Cellular 500G Module
Direct Installation
Guide
xx
ITRON INSTALLATION GUIDE
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Cellular 500G Module Direct Installation Guide
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Confidentiality Notice
Copyright © 2021 Itron, Inc. All rights reserved.
Confidential Information of Itron®, Inc., provided under nondisclosure obligations. The information
contained herein is proprietary and confidential and is being provided subject to the condition that (i) it
be held in confidence except to the extent required otherwise by law and (ii) it will be used only for the
purposes described herein. Any third party that is given access to this information shall be 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.
For more information about Itron or Itron products, go to www.itron.com.
If you have questions or comments about a software or hardware product, contact Itron Technical
Support Services.
Contact
Email: support@itron.com
Itron Access: https://access.itron.com
language.
ItronDocumentation@itron.com
Telephone Itron Technical Support North America: 1-877-487-6602
For technical support contact information by region, go to www.itron.com and select your country and
For suggestions, questions, or other feedback concerning Itron product documentation, contact us at:
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Contents
Cellular 500G Module Direct Installation Guide
Contents
New in This Document
1
Important Safety and Compliance Information
U.S. and Canadian Patent Numbers
U.S. Patent Numbers
Canadian Patent Numbers
USA, FCC Part 15 Spectrum Compliance
USA, FCC Class B-Part 15
Modifications and Repairs
Canada, ISED Spectrum Compliance
RF Exposure (FCC/ISED)
Transportation Classification
Modifications, Repairs, Installation, and Removal
2
About the Itron Cellular 500G Module
Lithium Battery Safety
Equipment Repairs
Intrinsic Safety
Electrostatic Ignition Hazard
Module Cleaning
Do Not Drop
Transmission Modes
Mobile High Power Mode
Mobile and Handheld Mode
(Optional) Hard-to-Read Mode
Module High Flow Event
Gas Day Take
Local Auditing
Low Battery Event/Alarm
Itron Security Manager
Functional Specifications
1
3
5
6
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7
7
8
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Contents
Operational Specifications
Device Firmware Functionality
Related Documents
3 Module Programming
Standard Configuration
Programming the Direct Mount Module
Itron Programs and Software Variables
Field Deployment Manager (FDM)
Mercury X-Blank Options
Check Endpoint Functions
Field Collection System (FCS) (Mobile Mode Only)
OpenWay Operation Center (OWOC)
4
Specific Meter Manufacturer Installation
Elster American Installation
Installation Overview
Sensus Meter Installation
Installation Overview
Residential Meter Mechanical Installation
Programming and Requirements Notes
13
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Contents
New in This Document
Revision
REV 000
Date
Description
July 2021
First date of publication.
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1Important Safety and Compliance Information
This section provides important information for your safety and product compliance.
U.S. and Canadian Patent Numbers
U.S. Patent Numbers
■ 4,614,945
■ 4,753,169
■ 4,768,903
■ 4,799,059
■ 4,867,700
■ 1,254,949
■ 1,267,936
■ 1,282,118
Canadian Patent Numbers
USA, FCC Part 15 Spectrum Compliance
This device complies with part 15 of the FCC Rules. Operation is subject to the following two
conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that may cause
undesired operation.
This device must be installed to provide a separation distance of at least 20 centimeters (7.9
inches) from all persons to be compliant with regulatory RF exposure.
USA, FCC Class B-Part 15
This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference in a residential installation. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and used in accordance with
the instructions, may cause harmful interference to radio communications. However, there is
no guarantee that interference will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception, which can be determined by
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1 Important Safety and Compliance Information
turning the equipment off and on, the user is encouraged to try to correct the interference by
one or more of the following measures:
■ Reorient or relocate the receiving antenna.
■ Increase the separation between the equipment and receiver.
■ Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
■ Consult the dealer or an experienced radio or TV technician for help.
Modifications and Repairs
To ensure system performance, this device and antenna shall not be changed or modified
without the express approval of Itron. Per FCC and ISED rules, unapproved modifications or
operation beyond or in conflict with these instructions for use could void the user's authority to
operate the equipment.
Canada, ISED Spectrum Compliance
Compliance Statement Canada
Déclaration de Conformité
This device complies with Innovation, Science and
Economic Development Canada (ISED) license-
exempt RSS standard(s). Operation is subject to the
following two conditions: (1) this device may not cause
interference, (2) this device must accept any
interference, including interference that may cause
undesired operation of the device.
Under Innovation, Science and Economic
Development Canada (ISED) regulations, this radio
transmitter may only operate using an antenna of a
type and maximum (or lesser) gain approved for the
transmitter by Industry Canada. To reduce potential
radio interference to other users, the antenna type and
its gain should be so chosen that the equivalent
isotropically radiated power (e.i.r.p.) is not more than
that necessary for successful communication.
Le présent appareil est conforme aux CNR d'Industrie
Canada applicables aux appareils radio exempts de
licence. L'exploitation est autorisée aux deux
conditions suivantes: (1) l'appareil ne doit pas produire
de brouillage, (2) l'utilisateur de l'appareil doit accepter
tout brouillage radioélectrique subi, même si le
brouillage est susceptible d'en compromettre le
fonctionnement.
Conformément à la réglementation d'Industrie Canada,
le présent émetteur radio peut fonctionner avec une
antenne d'un type et d'un gain maximal (ou inférieur)
approuvé pour l'émetteur par Industrie Canada. Dans
le but de réduire les risques de brouillage
radioélectrique à l'intention des autres utilisateurs, il
faut choisir le type d'antenne et son gain de sorte que
la puissance isotrope rayonnée équivalente (p.i.r.e.) ne
dépasse pas l'intensité nécessaire à l'établissement
d'une communication satisfaisante.
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1 Important Safety and Compliance Information
RF Exposure (FCC/ISED)
This equipment complies with radiation
exposure limits set forth for an uncontrolled
environment. This equipment should be installed
and operated with minimum distance 20 cm
between the radiator and your body. This
transmitter must not be co-located or operating
in conjunction with any other antenna or
transmitter.
Cet équipement est conforme aux limites
d'exposition aux radiations dans un
environnement non contrôlé. Cet équipement do it
être installé et utilisé à distance minimum de 20
cm entre le radiateur et votre corps. Cet émetteur
ne doit pas être co-localisées ou opérant en
conjonction avec tout autre antenne ou
transmetteur.
Transportation Classification
The Federal Aviation Administration prohibits operating transmitters and receivers on all
commercial aircraft. When powered, the Itron device is considered an operating transmitter
and receiver and cannot be shipped by air. All product returns must be shipped by ground
transportation.
Modifications, Repairs, Installation, and Removal
To ensure system performance, this device and antenna shall not be changed or modified
without the express approval of Itron. Any unauthorized modification will void the user's
authority to operate the equipment.
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.
Lithium Battery Safety
Warning! Follow these procedures to avoid injury 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 100° Celsius (212° Fahrenheit), crush, expose
to water, or incinerate the lithium battery.
■ Keep the lithium battery away from children.
■ Fire, explosion, and severe burn hazards
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1 Important Safety and Compliance Information
Equipment Repairs
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.
Intrinsic Safety
Warning! Substitution of components may impair intrinsic safety.
Electrostatic Ignition Hazard
Warning! Verify the area is not hazardous when installing, servicing, cleaning, or
touching the Itron device.
Module Cleaning
Warning! Clean only with a damp cloth.
Do Not Drop
Warning! While Itron modules are designed to withstand a drop, dropping the
module may damage the device and void the warranty.
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2About the Itron Cellular 500G Module
The Itron Cellular 500G module is a Cellular IoT (CIoT) gas module. It features cellular and RF
communication capabilities, delivering flexibility in reading options. It is designed to be read
under Itron IoT networks or by legacy ChoiceConnect™ handheld and mobile readers. With
new features for Network operation – including firmware download, high flow alarm, sub
hourly interval data and the ability to hop to a neighboring module for hard-to-read
applications and extended data storage – Itron’s Cellular 500G module offers additional value
while continuing to offer the highest in reliability, accuracy, battery life, security standards and
intrinsic safety that you have come to expect from the industry leader in gas modules.
This guide describes the steps for direct-mount installing the Itron Cellular 500G module.
Transmission Modes
This section describes the various modes available for the Cellular 500G modules.
Note: An FCC license is not required to read the modules.
The module supports 5, 15, 30, or 60-minute intervals and provides storage and reporting for
up to 62 days of 15-minute interval data and associated event data, or 8 months of hourly
interval data.
Note: Interval data options are dependent on the module's firmware version.
The module is designed to transmit 3 times a day with a 20-year battery life.
The module transmits a high-powered RF message every 60 seconds. In Mobile High-Power
Mode, the expected battery life is 20 years.
The module transmits a medium-powered RF message every 15 seconds. In Mobile and
Handheld Mode, the expected battery life is 20 years.
Mobile High Power Mode
Mobile and Handheld Mode
(Optional) Hard-to-Read Mode
The module transmits a high-powered RF message every 30 seconds. In Hard to Read Mode,
the expected battery life decreases to 15 years in this mode. The hard to read mobile mode
should only be used for exceptionally hard-to-read applications (such as meters installed on
rooftops or in sub-basements).
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2 About the Itron Cellular 500G Module
Module High Flow Event
Note: High Flow event functionality is dependent on the Cellular 500G module firmware
version.
High Flow is a configurable event/alarm that can alert a utility of an excessive flow of gas to
avoid potential hazardous events. The High Flow threshold can be configured using FDM
Tools.
Gas Day Take
Note: Gas Day Take functionality is dependent on the module firmware version. For more
information, see Device Firmware Functionality on page 13.
Gas Day Take (GDT) is critical to many natural gas utilities. GDT allows utilities to manage
deregulated gas purchases. While daily GDT reads can be used for various operations within
the utility, the primary time constrained business operation is to daily balance deregulated
(transport) customers. GDT requires GDT data from a percentage (typically a maximum of
10%) of the utility's customers at 9:00 a.m. Central Clock Time.
All collected data must be prepared and presented to deregulated marketers and customers
by 11:00 a.m. CCT to support the gas utility's deregulated tariff. If a deregulated marketer of
customer under or over-burns what they nominated for a given day, they may pay a daily
penalty. Customers require the previous day's GDT data to make adjustments to their next
day nomination to avoid penalties.
Local Auditing
Note: Local auditing functionality is dependent on the module's firmware version. For
more information, see Device Firmware Functionality on page 13.
The 500G module supports local data auditing of installation programming. Local auditing
features the listed characteristics.
■ Supports writing data (in both manufacturing and by FDM) to the module to support future
■ Auditing parameters include FDM User ID, number of dials, meter drive rate, unit of
installation programming auditing.
■ Reading the auditing data is supported locally.
measure, ERT count rate, rollover, and PComp.
■ Timestamping of auditing parameters.
■ Log access via COSEM only.
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Cellular 500G Module Direct Installation Guide
2 About the Itron Cellular 500G Module
Low Battery Event/Alarm
Note: For 500G modules, low-battery functionality is dependent on the module's firmware
version. For more information, see Device Firmware Functionality on page 13.
The 500G modules' low-battery events are flagged when the device reaches a 10% of battery
life remaining state. The event triggers an alarm configurable for asynchronous delivery to the
head end system.
Itron Security Manager
System security, provided by Itron Security Manager (ISM), applies to the RF communications
between the collection device and the Cellular 500G module.
There are two fundamental security processes used in the Itron Security Manager to ensure
system communication confidentiality and validity.
■ Authentication. Authentication is the process of confirming that an artifact is genuine or
valid. Authentication in the module is the process of verifying a request is from a valid
source and in its original form.
■ Encryption. Encryption is the process of transforming information to make it unreadable
to anyone who does not have a valid security key. There are two types of encryption,
symmetric and asymmetric. Symmetric encryption uses a shared key to decrypt or encrypt
information. Asymmetric encryption uses a private key to encrypt and a public key to
decrypt. Data transmissions over the network are protected using AES-256 encryption.
The 500G module supports the security model found in the GenX solution for both reading
and programming. If the modules are shipped without security enabled (ready to secure), the
utility can—at a later date—configure the modules for ISM enhanced security.
Important! Modules ordered pre-programmed with security injected and specified
as Zero Touch Deployment require that the installer rotates the wriggler five (5)
times to activate the module if the module is installed in a location with little or no
gas flow.
Functional Specifications
Functional specification
Description
Power source
Single "D" cell lithium batteries
Tamper detection
Tilt and cut cable
Regulatory and Standards
FCC compliance: Part 15.247, 15.249 (programming), 15.109
FCC ID: EWQ500GAC: for American/Rockwell Gas meters
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2 About the Itron Cellular 500G Module
Functional specification
Description
■ The Cellular modem is a Sierra Wireless HL7800 module.
– FCC ID: NLNHL78
ISED compliance: RSS-247, RSS-210 (programming), ICES 003
IC: 864D-500GAC: American/Rockwell
■ The Cellular modem is a Sierra Wireless HL7800 module.
–
IC: 2417C-HL78
Measurement Canada: Pending
Intrinsically safe per
Telemetering Equipment for use in Hazardous Locations, for Cl I, Div 1, Gp D
for Haz Loc, Temp Code T1, -40°C ≤ Ta ≤ +70°C.
Operational
All Cellular 500G modules operate pursuant to FCC, ISED cellular licensing,
and 3GPP defined, regulated cellular standards and networks.
Frequency: 3GPP Band 4 (744-787 MHz) / Band 13 (1710-2155 MHz) for
cellular operation; 902 to 928 MHz and 2400-2483.5 MHz ISM bands for RF
operation
Program frequency: 908 MHz
Product identification
Numeric and bar coded ERT type and serial number
Construction materials
Gray polycarbonate housing and back plate with encapsulated electronics
Operational Specifications
Operational specifications
Description
Operating temperatures
-22° to 158° F (-30° to +70° C)
Operating humidity
5 to 95 percent relative humidity
Data integrity
Verified in every data message
Device Firmware Functionality
This section lists the module device firmware information and lists functionality by version.
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2 About the Itron Cellular 500G Module
Part number
Firmware functionality
Global software
release
(GSR) version
FDM check
endpoint
firmware
version
FMW-7200-001
5.4
6.1.0
■ Support for American/Elster Residential meters
(Direct mount)
■ Support for Rockwell/Sensus Residential meters
■ GSR 5.4 functionality
■ Network/Mobile topology
■ 5, 15, 30-minute interval data
■ High flow alarm
■ Low battery alarm
■ Gas Day Take
■ Local auditing for dial and drive rate
Related Documents
■ 500G Module Remote Installation Guide
■ Field Deployment Manager Field Representative Guide
■ Field Deployment Manager Tools Configuration Guide
■ Field Deployment Manager Tools Mobile Application Guide
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3Module Programming
Caution: You must program the module before use.
Programming Itron modules requires an understanding of:
■ Your meter's drive rate and the number of dials
– The drive rate and number of dials is important for programming the module to count
correctly and roll over to zero at the correct time. For example, a four-dial, 2 cubic-feet
meter configuration will count two cubic-feet for each rotation and roll over to zero after
9999.99 where the ones place is equivalent to 100 cubic-feet.
■ How your system interprets the meter reading
– Some systems modify the consumption reading with the collection software. Other
times, the billing system is used to make modifications. If modifications are made in
both systems, issues may cause consumption reading errors.
Program the 500G cellular module using an approved programming device loaded with Field
Deployment Manager (FDM) software version 4.4 or later.
To enable enhanced security and for more complete programming information, see the Field
Deployment Manager Tools Mobile Application Guide.
Important! Modules ordered pre-programmed with security injected and specified
as Zero Touch Deployment require the installer to rotate the wriggler five (5) times to
activate the module if installing in a location with little or no gas flow.
Standard Configuration
Gas modules are capable of configurations that reduce battery life. Standard battery life is
based on the following configuration:
■ Hourly interval data
■ Interrogations of 3 times per day
■ 60-second receiver wakeup
■ Five firmware downloads over the life of the module
■ Network management and security overhead set to default timing
■ RF at capacity (2,000 maximum per cell)
■ Average of one two-way command/response per week
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Cellular 500G Module Direct Installation Guide
3 Module Programming
Programming the Direct Mount Module
Program the meter drive rate into the module using a compatible programming device.
1. Verify that you have the correct programming for your application: Mobile High-Power
Mode, Mobile/Handheld Mode, or Hard-to-read Mobile/Handheld Mode.
2. For all programming and Check Endpoint operations using a handheld computer, hold
the handheld as close to vertical as possible. For best success, keep the handheld within
six feet of the target module.
3. Programming parameters are based on the configuration file loaded into the programming
4. Read or Check the module using a compatible reading device.
– If the read result is higher than the number programmed in step 2, the module is
– If the read result is not higher than the number programmed in step 2, replace the
device.
counting correctly.
module.
Itron Programs and Software Variables
This section defines and clarifies possible system variables you may encounter in
programming modules.
Field Deployment Manager (FDM)
The following tables illustrate various FDM programming configurations and the endpoint
response to each setting.
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3 Module Programming
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3 Module Programming
Programming Example
Endpoint programmed for 6 dial, 1000 cubic feet CCF.
1. Enter the initial index read. For this example, the initial read is 123456 where 6 = 600 cubic
feet. After the initial programming, an endpoint read will result in a reading of 1234560
where the least significant digit is in 10's of cubic feet. Since counting is with a drive rate of
1000 cubic feet and the reading is transmitted in 10's of cubic feet, the last two digits of the
reading will not change.
2. Program the endpoint to 123456.
3. Read the endpoint. The result should be 1234560 with the zero added to put the reading in
4. Add one count. The result should be 1234660. Notice that the last two digits of 60 do not
10's of cubic feet.
change.
Mercury X-Blank Options
Endpoints (modules) can be programmed with one of the Mercury X-Blank options. There are
1, 2, 3, and 4 blank option available. Blank options are set up as a what-you-see-is-what-you-
get (WYSIWYG) configuration. The values are not set in cubic feet or cubic meter standards.
The Mercury X-Blank options are used in configurations where the system receives pulses
from a corrector or instrument that can change pulse values and has configurable display
digits. The Mercury-X Blank options allow users to program the endpoint to match the
configuration of the corrector or instrument.
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3 Module Programming
Check Endpoint Functions
The FDM Check Endpoint function triggers users to input the number of dials and drive rate if
a Check Endpoint is requested for an endpoint programmed for 5, 6, or 7-dial meter
configurations. The request to input the dial and drive rate information happens only if the
system has more than one option using the same count rate and rollover variable enabled in
their FDM business unit.
Note: Itron recommends that users only enable the configurations used by your business
unit. Having only one meter configuration option enabled (with the endpoint variable being
checked in the FDM business unit) eliminates the need to enter the number of dials.
Field Collection System (FCS) (Mobile Mode Only)
In FCS, a Read Type Code can be assigned to a meter session. The Read Type Code in
conjunction with the Endpoint Type is used to determine how the endpoint reading is
formatted using the Endpoint Translation table in FCS. The Endpoint Translation table is a
configurable table that is used to determine the truncation factor and multiplier for each
reading. A default Endpoint Translation is defined for each type of endpoint supported by FCS
(ReadType of 00 for each EndpointType). If the default Endpoint Translation is not formatting
the read correctly, an additional Endpoint Translation can be defined to properly format the
read.
Since the Endpoint Translation Code is based on the Read Type Code and the Endpoint
Type, changing from a 40-series endpoint to a 100-series endpoint can cause the reading to
be truncated differently. If you are having issues with your reading after a change out, check
your Read Type Codes and Endpoint Translation Codes.
OpenWay Operation Center (OWOC)
The OpenWay Operation Center (OWOC) collects the raw reading and passes it on without
making any formatting changes.
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4Specific Meter Manufacturer Installation
This chapter provides module installation instructions for the compatible meter types. See
each section for a listing of those meters.
Important! Modules ordered pre-programmed with security injected and specified
as Zero Touch Deployment require that the installer rotate the wriggler five (5) times
to activate the module if installing in a location with little or no gas flow.
Elster American Installation
Table 1 Residential direct-mount Cellular 500G Module
This section provides instructions to install the residential modules on the following compatible
Elster American meters. Some meter manufacturers provide mounting kits and installation
procedures for their meters. If the Elster American meter to the module installation instructions
are not available, follow the installation procedures in this section.
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4 Specific Meter Manufacturer Installation
Meter model
Meter notes
Gas module notes
Itron part
number
ECG-7200-
001
W75AL Aluminum case
AC-175 Aluminum case
AL-175 Aluminum case
ALC-175 Aluminum case
AT-175 Aluminum case
AT-210 Aluminum case
AL-225, Canada only Aluminum case
5B-225 Aluminum case
AC-250 Aluminum case
AL-250 Aluminum case
AM-250 Aluminum case
AR-250 Aluminum case
AT-250 Aluminum case
AL-310 Aluminum case
AL-350 Aluminum case
AL-425 Aluminum case
AC-630 Aluminum case
AC-800 Aluminum case
Must cut 1/16" off the end of
the module wriggler drive post
which will make the module
incompatible with other 2-ft.
drive meters.
ECG-
7200-001
Installation Overview
Installing the direct mount module to an Elster American meter involves four tasks.
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4 Specific Meter Manufacturer Installation
1. Removing the index cover and preparing the meter for installation.
– Preparing the meter requires:
• A flat-head screwdriver
• A scraping tool
2. Assembling the index and module.
3. Programming the module. See Module Programming on page 15 for programming
instructions and items needed to program the module.
4. Connecting the module to the meter. Connecting the module to the meter may require the
following materials:
– A compatible index
– Small and medium flat-blade or Phillips screwdrivers
– Side-cutting pliers or wire snips
– (Optional) meter seals, wire seal, and seal press
– 11/32-inch nut driver or other blunt tool
– Replacement screws (for replacement screw information, see Installation
Requirements on page 1.
Module configuration with the meter is dependent on your system application. See the Elster
American meter configuration information.
Sensus Meter Installation
This section provides the information to install the module on a Sensus meter. These
instructions apply to 11-tooth, 16-tooth, and 18-tooth residential Sensus gas modules.
Note: Sensus meters are also known as Invensys, Equimeter, or Rockwell. For these
instructions, all meter types are referred to as Sensus meters.
Figure 1 Sensus residential Cellular 500G module
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4 Specific Meter Manufacturer Installation
Sensus 11-tooth
Sensus 16-tooth
Sensus 18-tooth
The listed Sensus meters are compatible with the gas modules.
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4 Specific Meter Manufacturer Installation
Meter model
11-tooth
ECG-7200-002
Gas module notes
24 and 30-tooth gears are not
compatible
S-110
T-110
S-120
T-120
R-175
R-200
RT-200
S-200
RC-225
RT-225
RC-230
RT-230
250
R-275
RT-275
S-275
310
R-315
Cubix250
MR-7 (Cubix250 Metric)
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Meter model
MR-8 (R-275 Metric)
MR-5 (S275 Metric)
MR-9 (R-315 Metric)
MR-12 (415 Metric)
RT-100
S-175
S-190
RT-360
Cellular 500G Module Direct Installation Guide
4 Specific Meter Manufacturer Installation
RCM-230 (RC-230 Metric)
16-tooth
ECG-7200-003
Gas module notes
24 and 30-tooth gears are not
compatible
18-tooth
ECG-7200-004
24 and 30-tooth gears are not
compatible
18-tooth.
ECG-7200-004
24 and 30-tooth gears are not
compatible
Older meters
may have
module-to-
meter
mounting hole
variations that
make them
incompatible.
415
Installation Overview
Installing the 500G direct mount module to a Sensus meter involves four tasks.
1. Removing the index cover and preparing the meter for installation.
– Preparing the meter requires:
• A flat-head screwdriver
• A scraping tool
2. Assembling the index and module.
3. Programming the module. See Module Programming on page 15 for programming
instructions and items needed to program the module.
4. Connecting the module to the meter. Connecting the module to the meter may require the
following materials:
– A compatible index
– Small and medium flat-blade or Phillips screwdrivers
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– Side-cutting pliers or wire snips
– (Optional) meter seals, wire seal, and seal press
– 11/32-inch nut driver or other blunt tool
– Replacement screws (for replacement screw information, see Installation
Requirements on page 1)
Module configuration with the meter is dependent on your system application. See Sensus
meter documentation for more information.
Residential Meter Mechanical Installation
This section describes the module mechanical installation on the residential Sensus meter.
1. Remove the four index cover screws and the index cover from the Sensus meter.
Alternate screw removal following the numbered pattern as shown in the illustration.
2. Examine the index cover screws. If they are 5/8-inch long and not corroded, keep them to
attach the module assembly. If the screws are not the correct length or if the screws are
corroded, discard them.
3. Remove one index mounting screw completely. Hold one hand under the index to catch
the screw. While removing the other mounting screw, pull the index away from the meter
to keep the index backplate against the back of the screw. Remove the screw completely
after the index is free of the meter.
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4. Set the index aside where it will not be damaged or fill with dirt, rain, or snow. You will
mount the index on the module later in this procedure.
5. Verify that the index mounting screws not corroded. If the screws are the not corroded,
retain for later use. If you discard the original screws, use the correct replacement screws.
For screw replacement information, see Installation Requirements on page 1.
6. Remove the old gasket, gasket residue, and dirt from the meter (if applicable). The meter
face must be free of gasket residue or dirt before you install the module.
7. Separate the module housing from the clear cover by pulling the cover straight out from
the housing. Set the module cover aside where it will not be damaged or fill with rain, dirt,
or snow. You will replace the cover later in this installation procedure.
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8. Place the index drive gear (1) in the shaft gear cup (2) of the module. The example shows
an 11-tooth drive gear. Your index may be a 16- or 18-tooth gear. Use the appropriate
module for your specific meter.
Warning! Indexes have varying drive mechanism styles. Failure to align the
module shaft with the index drive post can cause binding and lead to poor
registration or meter failure. To verify proper engagement of the index to the
module shaft, spin the wriggler one clockwise rotation, then one-
counterclockwise rotation. Do not spin the shaft more than one complete
rotation. The shaft should spin freely, with little or no resistance.
9. After the index drive gear is aligned and inserted into the shaft gear cup, the mounting
holes will line up.
10. Using the original index mounting screw or a replacement screw (if necessary), place one
6 - 32 x 5/8-inch screw into the index right mounting screw hole.
11. Attach the screw to the module housing right-index mounting post just enough to hold the
screw and the right end of the index in place.
12.
Install and tighten the left index mounting screw.
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13. Tighten the right index mounting screw completely. Install and tighten both index mounting
screws evenly.
14. Slide the module cover over the index and housing. Verify that the cover is installed
correctly. The module label should be clearly visible and easily read.
15. After the module programming is complete, attach the module assembly to the Sensus
meter. For programming information, see Programming the Direct Mount Module on page
16.
16. Place the module assembly against the front of the meter at angle.
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Warning! Failure to correctly align the meter drive gears and module drive
gears can cause binding and lead to poor registration or meter failure. If there is
a gap between the module gasket and the meter, it may be the that drive gears
of the module assembly's wriggler are not correctly aligned with the meter drive
gears. Remove the module assembly and repeat the alignment procedure. You
must engage the module wriggler with the meter drive gears.
17.
Install and tighten the module-to-meter mounting screws in an alternating pattern. Use the
original mounting screws if they were the correct size and not corroded. If you discarded
the original screws, use the correct replacement screws.
Caution: As the module assembly is secured into its final position on the meter,
shifting may occur due to existing tolerances within the mounting screw holes.
To ensure full module wriggler gear to meter gear engagement, push the
module to the right while tightening the screws in the following pattern.
a. Align the top right mounting screw hole on the meter with the top right screw hole on
the module.
b.
Insert the top right cover mounting screw and tighten the screw enough to hold the
module assembly in place. Do not completely tighten the screw.
c. Rotate the module assembly counterclockwise until the remaining three module screw
holes line up with the holes in the meter.
18.
Install the remaining three mounting screws and tighten them as described here and
shown in the illustration.
Important! Meter manufacturers: torque the mounting screws 15 to 20 inch-
pounds.
1.
Insert lower left mounting screw (2) and tighten to snug position.
2. Tighten upper right mounting screw (1,3) to snug position.
3.
Insert upper left mounting screw (4) and tighten to snug position.
4.
Insert lower right mounting screw (5) and tighten to snug position.
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5. Tighten each mounting screw evenly.
19. Place a new tamper seal over the two screws with tamper seal cups. Press the new
tamper seals into place using an 11/32-inch nut driver (or similar blunt tool).
20. Complete any necessary paperwork and properly dispose excess installation materials
and scrap from the customer premises.
This completes installation of the module installation on the Sensus meter.
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Programming and Requirements Notes
Caution: You must program the module before use. For programming information,
see Programming the Direct Mount Module on page 16.
The module is programmed based on the meter's drive rate. Take note of the index drive rate
shown on a lower dial on the index. Sensus meter index drive rates are typically 2-cubic feet.
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