DRAFT Series 4000 MTU Maintenance and Operation Manual Y20456-TUM Rev. A www.Aclara.
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DRAFT Proprietary Notice Information contained in this document is private to Aclara Technologies LLC, an Ohio limited liability company (Aclara). This information may not be published, reproduced, or otherwise disseminated without the express written authorization of Aclara. Any software or firmware described in this document is furnished under a license and may be used or copied only in accordance with the terms of such license.
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DRAFT WARNINGS, CAUTIONS, AND NOTES Always consult and adhere to all local and national safety codes, regulations, and standards.WARNING, CAUTION and Note statements are used throughout this manual to emphasize important and critical information to help you ensure safety and prevent product damage.These statements are defined below. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious physical injury.
DRAFT Conformité FCC/IC AVERTISSEMENTS , MISES EN GARDE ET REMARQUES Toujours consulter et respecter les codes, règlements et normes de sécurité locaux et nationaux. Des AVERTISSEMENTS, MISES EN GARDE et remarques sont utilisés tout au long de ce guide pour souligner l'information importante et critique qui vous aidera à assurer la sécurité et à prévenir les dommages au produit. Ces énoncés sont définis ci-dessous.
DRAFT Table of Contents Chapter 1: STAR Network Overview 1 Two-Way Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MTU/DCU Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DCU/NCC Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Chapter 2: Series 4000 Operation Configuration . . . . Read Intervals . . . . Time Synchronization. Security . . . . . . . Hardware . . . . . Software . . . . . . Alarms . . . . . . .
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DRAFT STAR NETWORK OVERVIEW The STAR Network is a fixed-network, Advanced Metering Infrastructure (AMI) that automatically reads water and gas instruments. The STAR Network uses a 3-tier configuration to read and transmit information between the measuring instrument and the utility office. The three tiers of the STAR Network are: 1. Meter Transmission Units (MTUs) 2. Data Collection Units (DCUs) 3.
Two-Way Communications 2 DRAFT Series 4000 Maintenance and Operations Manual
DRAFT SERIES 4000 OPERATION The Series 4000 MTU is designed to connect with a Honeywell ERX pressure monitor, a Honeywell Mini-AT volume corrector, or a Mini-Max volume corrector. In addition to a 10 item audit trail, the Series 4000 allows the user to perform on-demand reads and reconfigure the instrument and the MTU via the NCC. It contains a replaceable battery, two LEDs, and a USB port used for commissioning and reading information from the MTU locally.
DRAFT Security Security The 4000 Series MTU provides options for both hardware and software security. Hardware The Series 4000 MTU enclosure is designed to allow the user to secure the door with a lockout device. Software The MTU may be configured to send the following tamper alarms to the NCC: 1. Interface tamper (configuration change via USB port) 2.
DRAFT Series 4000 Operation Alarms In addition to the tamper alarms, the MTU may also be configured to send the following alarms to the NCC: Last Gasp The MTU will regularly report battery voltage values to the NCC. When this value falls below a specified value, the NCC will display a Low Battery notification. Aclara recommends changing the battery promptly when a low battery alarm is received. Please see Maintenance on page 35 for more information.
DRAFT Trend Mode Transmit Interval The transmit interval for Trend Mode is pre-configured at six times the read interval. That is: • If a 1 minute read interval is selected, the transmit interval will be 6 minutes. • If a 5 minute read interval is selected, the transmit interval will be 30 minutes. If Trend Mode is canceled from the NCC or if the MTU receives a clear pressure alarm signal from the instrument, the MTU will notify the NCC that only six more readings will be received in Trend Mode.
DRAFT STAR PROGRAMMER SOFTWARE The STAR Programmer application is used along with a suitable tablet or laptop and a USB cable (Aclara part number 070-1700) to commission an MTU after installation or to turn an MTU off prior to storage or relocation. This section provides information on the USB communication interface and how to interact with the MTU using this application.
USB Port DRAFT Communication LEDs. Two LEDs located to the right of the battery and above the COMP1 connector indicate the direction of communication through the USB port. • The left LED (LED 1) indicates when data is sent from the tablet or laptop through the USB port to the Series 4000 MTU. • The right LED (LED2) indicates when data is sent from the MTU out through the USB port to the tablet or laptop.
DRAFT STAR Programmer Software Software The STAR Programmer application may be used to commission an MTU after installation, read and troubleshoot an MTU in the field, or to turn off an MTU if it will not be in use for an extended period of time. Actions performed using the STAR Programmer software are logged and uploaded to the Network Control Computer (NCC) for verification at the end of each shift.
Software DRAFT Application Installation Use the following procedure to install the STAR Programmer software on a suitable tablet or laptop. 1) Double-click the STARProgrammerPC.msi file. 2) Click Next to begin the STAR Programmer Setup Wizard.
DRAFT 3) Verify the installation location, and click Next. 4) Click Next to initiate the installation.
Software DRAFT 5) Wait while the STAR Programmer is installed. 6) Click Close after the Installation Complete confirmation appears.
DRAFT STAR Programmer Software XML File Installation Use the following procedure to install the XML files that accompany the STAR Programmer application. 1) Refer to the table below when selecting the appropriate STARXML.msi file for the installation. NOTE: Multiple STARXML installations cannot coexist on the same machine. Installation Type .MSI File PC Interactive Mode - With Encryption STARXMLPCTEST.msi PC Interactive Mode - Without Encryption STARXMLPCTESTNONENCRYPT.
Software DRAFT 4) Verify the installation location, and click Next. 5) Click Next to initiate the installation.
DRAFT 6) Wait while the XML files are installed. 7) Click Close after the Installation Complete confirmation appears.
Software DRAFT Connection Use the following procedure to connect a tablet or laptop to a Series 4000 MTU and open the STAR Programmer application. 1) Remove any security hardware from the MTU door. 2) Open the door of the MTU. 3) 16 4) Connect the remaining end of the USB cable to the Series 4000 MTU. 5) Open the STAR Programmer application. 6) Leave the Operator and Password fields blank and click Submit. Connect the USB cable to the laptop or tablet.
DRAFT STAR Programmer Software Operation The STAR Programmer menu functions for Series 4000 MTUs are Read MTU, Turn Off MTU, Add MTU, Install Confirmation, and Replace Battery. Each of these functions are described in the following sections. Read MTU Turn Off MTU This option allows the user to read information from the MTU and the instrument. It will also write configuration settings to the instrument.
Software DRAFT Add MTU Select this option to commission a new MTU or an MTU that was turned off. 1) 3) Enter the 10-digit Account Number into the Gas Network Node (GNN) field. Select Add MTU. the Instrument Type field has auto-populated, and click OK. 4) Verify 2) Click OK to read the MTU and instrument. 5) Wait while the software commissions the MTU. This may take several minutes.
DRAFT 6) Once commissioning is complete, the software will return the current values allowing you to confirm the settings. STAR Programmer Software 7) Click OK to confirm the log entry and return to the Main Menu. 8) To close the STAR Programmer application, select File > Exit.
Software DRAFT Replace MTU To replace an existing MTU or after installing a new battery in an MTU that has been without power for an extended amount of time, use the Replace MTU option in the STAR Programmer application. 1) 3) Enter the 10-digit Account Number into the Gas Network Node (GNN) field. Select Replace MTU. the Instrument Type field has auto-populated, and click OK. 4) Verify 2) Click OK to read the MTU and instrument. 5) Wait while the software commissions the MTU.
DRAFT 6) Once commissioning is complete, the software will return the current values allowing you to confirm the settings. STAR Programmer Software 7) Click OK to confirm the log entry and return to the Main Menu. 8) To close the STAR Programmer application, select File > Exit.
Software DRAFT Install Confirmation Replace Battery This option allows the user to confirm that the MTU can communicate with the available DCUs and to see information about the MTU, DCU, and the communication between the two. Use the following procedure after replacing the battery in the MTU. 1) 2) Select Replace Battery. 2) Click the OK button to initiate the process. 3) Wait while the STAR Programmer reads the MTU. 4) Click OK to log the activity and return to the Main Menu.
DRAFT HARDWARE INSTALLATION Aclara offers kits to mount the Series 4000 MTU to a wall or to a pipe with an outside diameter of 2 "- 3". Use the corresponding instructions to mount a Series 4000 MTU using one of these kits. NOTE In addition to the mounting hardware, the installation kits also include one 10' length of conduit, two conduit fittings, one 12' length of five conductor cable, and one 12’ length of two conductor cable.
Wall Mount DRAFT Solid Wall 3) Drill holes at the four marked locations with a ¼" Wedge Bit. 4) Insert a wedge bolt through a flat washer and one of the mounting holes on the MTU. 5) Thread the bolt partially into the appropriate hole drilled in step 3. 6) Repeat steps 4 and 5 for the remaining bolts. 7) Tighten all four wedge bolts to 27-33 ft-lb. Follow this procedure to mount the MTU to a solid wall.
DRAFT Hollow Wall Hardware Installation 3) Drill holes at the four marked locations with a ½" drill bit. 4) Insert the anchor end of one wall anchor through one of the drilled holes. 5) Pull the anchor until it is tight against the back side of the wall surface. Then slide the cap forward until it is flush with the wall. Follow this procedure to mount the MTU to a hollow wall.
DRAFT Wall Mount 6) Snap off the excess strap by pressing the top strap up and the bottom strap down. 7) Repeat Steps 4-6 for the three remaining anchors. 8) Place a flat washer on each of the bolts, and insert the bolts through the mounting holes of the MTU. 9) Thread each bolt into the appropriate anchor. 10) Tighten 26 each bolt to 5-7 ft. lbs.
DRAFT Hardware Installation Pipe Mount Pipe Mount Kit #109-2015-001M-21 Item Description Quantity A Bracket assembly (5/16"-18 bolt, metal washer, nylon washer, & bracket) 2 B 2 "- 3" Screw-drive tube clamp 2 Series 4000 Maintenance and Operations Manual 27
Pipe Mount DRAFT Special Tools In addition to standard hand tools and safety equipment, the Pipe Mounting kit also requires the following: • 0-20 ft-lb Torque-limiting wrench • 0-10 in-lb Torque-limiting wrench or screwdriver 1) Thread one of the clamps through both slots in one of the brackets and around the pipe. 2) Rotate the bracket to the desired mounting position and tighten the clamp just enough to maintain bracket position.
DRAFT Hardware Installation Wiring Use the following instructions to connect the MTU to a Honeywell electronic pressure monitor or volume corrector.
Wiring DRAFT Conduit & Fittings The cable connecting the MTU to the instrument must be routed through the included conduit. Use the following procedure to install the conduit. 8) Secure the fitting to the MTU with the lock ring. Tighten the ring to 15-19 in-lb. 9) Route the conduit to the instrument. CAUTION Do not bend the conduit smaller than 1) Remove the nut, sealing ring, and ferrule from one of the conduit fittings. 2) Slide the nut and sealing ring over the end of the conduit.
DRAFT Hardware Installation MTU Connections Use the following information when connecting the cables to the MTU. 1) Route the cable through the conduit. Optional Power 2) Use the following information to connect the cable wires to the MTU mating connector. Secure each wire into the connector by tightening the corresponding set screw.
DRAFT Wiring Instrument Connections Use the information for the appropriate meter type to connect the MTU cable(s) to the instrument. Refer to the Electrical Connection Parameters table for electrical parameters of each connector. Mini-Max or ERX Mini-AT Use the following information to connect the MTU cable to a Honeywell Mini-Max volume corrector or ERX pressure monitor. Use the following information to connect the MTU cable to the TB2 connector on a Honeywell Mini-AT volume corrector.
DRAFT Hardware Installation Commissioning After installing and connecting the MTU to the instrument, it is necessary to commission the MTU using the Add MTU function of the STAR Programmer software. Please refer to the STAR Programmer Software section on page 7 for more information on connecting the STAR Programmer and adding an MTU.
Commissioning 34 DRAFT Series 4000 Maintenance and Operations Manual
DRAFT Maintenance MAINTENANCE The Series 4000 MTU is designed to be largely maintenance free. Periodic replacement of the battery, however, will be necessary over the life of the MTU. The Series 4000 MTU is powered by a 3.6V lithium, D cell battery (Aclara part number 042-0049). The NCC reports regular battery voltage readings, and also provides a low battery warning to provide ample time for the utility to replace a battery without loss of data.
