ChoiceConnect CCU 100 and Repeater 100 Installation Guide
Identification CCU 100 and Repeater 100 Installation Guide 10/25/2010 TDC-0971-000 Copyright © 2010 Itron, Inc. All rights reserved. Confidentiality Notice 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.
Contents Before You Begin........................................................................................................... v Documentation Conventions...........................................................................................................v Related Documents....................................................................................................................... vi Chapter 1 CCU/Repeater Basics ........................................................................
Contents Tower Installation Overview................................................................................................34 TCU Components...............................................................................................................35 AC Tower Installation Diagram ...........................................................................................38 Solar Powered Installation .................................................................................................
Before You Begin Important Proper installation of the CCU/Repeater ensures trouble-free operation of the Itron Fixed Network system. The installation of both the collector and repeater must be done by professional installers. Documentation Conventions This document uses the following conventions. Convention Example Key presses are in bold. Click OK to finish. Menu paths are in bold. Select Start > File > Save As. Computer commands to be typed by the user are in a monospace font.
Before You Begin Related Documents For more information about CCUs/Repeaters and the Fixed Network, see the following: • Collector Configuration Application v4.0 User Guide Fixed Network system administrators must use this document to properly configure CCU 100s before they are installed in the field. • Network Collection Engine v4.0 User Guide • Motorola R56 Manual- Standards and Guidelines for Communication Sites Available from Motorola.
CHAPT ER 1 CCU/Repeater Basics The CCU 100 (also known as a cell control unit or collector) and the Repeater 100 are configurable for different installation locations, including: • On a water or communications tower. • On a pole (such as an electricity or light pole). • On a wall (indoor or outdoor). • On a pipe (between 2 and 3.5 inches in diameter). Integrated mounting and coupling brackets secure the device in high winds and under heavy ice loads.
Chapter 1 CCU/Repeater Basics CCU/Repeater Components The CCU 100 and Repeater 100 come in two basic configurations, non-remote and remote. The remote CCU/Repeater configuration replaces the internal antennas with external antenna connectors allowing both GPS and WAN antennas to be mounted in a remote location. In the case of the Repeater 100, only an external GPS connection is provided; a WAN modem is not present in a repeater.
CCU/Repeater Components Item 1 Description CCU/Repeater module Processes data from the antennas and relays it on to the Fixed Network Application Software. Only authorized Itron personnel may open this module. 2 Endpoint antenna This 900MHz antenna receives messages from and sends messages to endpoints and repeaters in the network. The connection for this antenna is a Type N female. 3 CCU/Repeater label Displays the collector identification number, model number, and other associated information.
Chapter 1 CCU/Repeater Basics Itron recommends using a handheld GPS unit to verify that your GPS antenna mounting location can receive a signal from at least three satellites. If you are using a GPRS WAN backhaul, Itron recommends testing the GPRS antenna at your desired installation to ensure that GPRS service is available at that location. For more information, see GPS and WAN Coverage on page 8.
CCU/Repeater Components Endpoint Antenna The Endpoint antenna transmits and receives data messages from endpoints and repeaters in the network. There are five possible antennas (two direct attached antennas and three remote antennas) that may be used for the endpoint radio link. • A standard vertically or horizontally polarized antenna that is directly attached to the CCU/Repeater.
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CHAPT ER 2 Planning a CCU/Repeater Installation This chapter describes how to prepare for a CCU/repeater installation. Installation Profiles The CCU/Repeater can be installed in a variety of configurations and locations. Depending on the installation location, the CCU or Repeater components may be installed all in the same place (as an integrated solution), or the antennas may be installed remotely from the CCU/Repeater (as a distributed solution).
Chapter 2 Planning a CCU/Repeater Installation Siting CCUs/Repeaters CCUs/Repeaters are installed in the field on a variety of surfaces, such as wooden or metal walls, metal pipes, fence railing, and utility poles. When determining where to place the CCU/Repeater, there are four primary considerations: • Siting for optimum RF reception. • Siting for optimum GPS and/or WAN reception. • Availability of Ethernet connection (if required). • Availability of power connection.
Siting CCUs/Repeaters To ensure the best possible signal, avoid installing the CCU/Repeater or the remote antennas in the following ways: • Adjacent to or between tall buildings, signs, towers, or bridges. • Near swaying limbs, branches, or cables that could strike and damage the antenna. • Between, beneath, or near highway overpasses, elevated train platforms, or tunnels. • Near objects or devices attached to the same pole.
Chapter 2 Planning a CCU/Repeater Installation • The antenna receives and transmits in all directions. Any objects such as building walls, nearby metal surfaces or other obstructions will interfere with the proper operation of the antenna. • Do not mount the antenna near existing RF radiating antennas. If existing RF radiators are nearby, the horizontal separation distance to the radiator must be a minimum of 100 feet and/or 10 feet of vertical separation.
Lightning Arrestor The recommended procedure for grounding the antenna system is as follows: • Mount a copper ground bar near the antenna. This is the top ground bar. • Mount a second copper ground bar near the CCU/Repeater. This is the bottom ground bar. • Connect the two ground bars with a #6 gauge green jacketed stranded wire or a #2 solid copper wire. • Ground the antenna mount and the top coaxial ground kit to the top ground bar.
Chapter 2 Planning a CCU/Repeater Installation The top and bottom ends of the coaxial cable attached to the tower should be electrically grounded with kits for lightning protection. The antenna input connection cannot serve as the top ground point. For cable lengths in excess of 200 feet, ground the vertical cable run at the midpoint and then each additional 200 feet.
Materials Not Provided by Itron Materials Not Provided by Itron The following materials are not provided by Itron in the CCU/Repeater kit, but are required for installation. Please acquire these items prior to beginning an installation. • Coaxial cable on page 13 • Connectors on page 14 • Mounting hardware on page 14 Coaxial Cable When remote mounting the antennas, coaxial cable must be supplied to connect the antenna to the CCU/Repeater.
Chapter 2 Planning a CCU/Repeater Installation Antenna Sweep Test After remote antenna installation perform an antenna system sweep test and verify that VSWR (voltage standing wave ratio) does not exceed 1.5:1. For more information, see Perform an Antenna Sweep Test on page 55. Caution All coaxial cable used to connect an antenna to the CCU/Repeater must be properly grounded at the top and bottom of the coaxial line. Additionally, any cable lengths of 200 feet or greater must be grounded each 100 feet.
Materials Not Provided by Itron Mounting Hardware Depending on your installation location and configuration, the following mounting hardware must be supplied by the installer to properly attach the CCU/Repeater to the mounting surface. Caution Since each installation is unique, you must ensure that the mounting hardware you supply can securely support the CCU/Repeater. The CCU/Repeater (minus attachment hardware) weighs 7 pounds.
Chapter 2 Planning a CCU/Repeater Installation 16 CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
CHAPT ER 3 Installing the CCU/Repeater This chapter shows you how to install a CCU/Repeater in the field, using the Itronrecommended installation method. The CCU/Repeater can be installed in a variety of ways. Several different CCU/Repeater installation profiles are shown in this chapter, for both mains powered and solar powered CCU/Repeaters. Warning Before installing a CCU/Repeater, ensure that the selected location can support the weight of the CCU/Repeater and mounting hardware.
Chapter 3 Installing the CCU/Repeater Attaching the GPS/WAN Remote Antennas The GPS and WAN remote antennas can be attached to pipes, poles, walls, and davit arms. A typical pole mount assembly is shown below. To attach the GPS/WAN remote antennas • For step-by-step assembly instructions, see the GPS/WAN Remote Antenna Mounting Kit Assembly Guide included with the GPS/WAN Remote Antenna Mounting Kit.
Attaching the Direct Mount Endpoint Antenna Attaching the Direct Mount Endpoint Antenna Attach the direct mount endpoint antenna before mounting the CCU/Repeater in its permanent location. To attach the direct mount endpoint antenna 1. Screw the antenna onto the top of the CCU/Repeater. Be careful not to cross-thread the connectors. Do not over tighten. 2. Slide the antenna sleeve over the antenna, ensuring that the front of the antenna sleeve (1) is to the front of the CCU/Repeater.
Chapter 3 Installing the CCU/Repeater 3. Using the included screws, washers, and lock washers, screw the antenna sleeve to the top of the CCU/Repeater. Tighten the screws to 5 to 6 in/lbs.
Attaching the CCU/Repeater Attaching the CCU/Repeater The CCU/Repeater may be attached to a variety of surfaces. See the following sections for diagrams showing some of the possible configurations. • Pipe mount on page 22 • Pole mount on page 24 • Wall mount on page 26 • Davit arm mount on page 27 Mounting Hardware This set of hardware can be adapted to mount the CCU/Repeater in many different locations.
Chapter 3 Installing the CCU/Repeater Pipe Mount The image below illustrates a typical vertical pipe installation. The CCU/Repeater may also be attached to a horizontal pipe. In this case the CCU/Repeater mounting plate is attached to the vertical pipe with the mounting brackets and the CCU/Repeater enclosure is secured to the mounting plate. The power cable is connected to the available AC service with either the un-terminated pigtail power cable or the grounded outlet plug power cable (optional).
Attaching the CCU/Repeater 2. Insert the mounting disc into the mounting plate keyhole. 3. Using the provided set screws, secure the CCU to the mounting plate in the upright position.
Chapter 3 Installing the CCU/Repeater Pole Mount If the vertical pipe or pole exceeds 6.75 inches in diameter, metal bands may be used in place of the mounting brackets to secure the mounting plate to the pipe or pole. Two sets of slots (1.5 in. long) on the mounting plate are provided for the metal bands. If the pole is large in diameter, Itron recommends that the endpoint antenna be remote mounted to achieve optimum RF performance. To mount the CCU/Repeater on a pole 1.
Attaching the CCU/Repeater 2. Using the provided set screws, secure the CCU to the mounting plate in the upright position. 3. Using two steel straps, attach the mounting plate to the pole.
Chapter 3 Installing the CCU/Repeater Wall Mount The following image illustrates a wall mount installation. In this scenario two brackets are secured to the flat wall surface and the CCU/Repeater is bolted to the brackets. The power cable may be connected to a standard outlet or other available AC service. It may be necessary to use the remote antenna kit to achieve optimum RF performance and GPS coverage if mounted indoors or if the wall obstructs the desired RF path.
Attaching the CCU/Repeater Davit Arm Mount The figure below illustrates a typical utility pole or street light pole installation. The CCU/Repeater is mounted on a davit arm or the street light arm. Two types of power connections are typical. A photocell adapter cable may be used when the CCU/Repeater is mounted on a street light arm. This cable plugs into the photocell sensor of the street light.
Chapter 3 Installing the CCU/Repeater 2. Insert the mounting disc into the mounting plate keyhole. The following photos are shown off the davit arm for clarity. 3. Using the provided set screws, secure the CCU to the mounting plate in the upright position.
Connecting Cables Connecting Cables Connect the remote antenna cables (if needed), Ethernet cable (if needed), and grounding wire. Because of the variable requirements for cable length, cables are not provided by Itron. Important All coaxial cable connections must be properly weather-proofed per industry standards unless otherwise specified. If the CCU/Repeater is installed indoors, only the connections located outside need to be weather-proofed. To connect cables 1.
Chapter 3 Installing the CCU/Repeater 3. If you are using a remote endpoint antenna, attach the endpoint antenna cable to the connector on the top of the CCU/Repeater. Important Using weatherproof tape, wrap the remote endpoint antenna connection on the top of the CCU/Repeater. Wrap from the CCU/Repeater up to the antenna cable. 4. If you are using an Ethernet backhaul, attach the Ethernet cable ensuring the weathertight connector is properly secured.
Installing the Battery 2. Plug in the four pin battery wiring harness. The harness should snap into place, providing a secure connection. 3. Slide the battery into the battery compartment. 4. Replace the battery compartment cover, and torque the screws to 6 inch-pounds.
Chapter 3 Installing the CCU/Repeater Providing Power The final step of the CCU/Repeater installation is to provide power to the CCU. Depending on the CCU/Repeater model, either a two pin cable (DC), three pin cable (AC), or a five pin cable (solar) is required. Caution Do not move or tilt the CCU for one minute after connecting power. Moving or tilting a CCU too soon after connecting power may cause it to reset to the factory image. To provide power 1. Plug the appropriate cable in to the CCU/Repeater.
AC Mains Non-Remote Installation Diagram AC Mains Non-Remote Installation Diagram Tower Installation Warning Before installing a Tower CCU, ensure that the selected location can support the weight of the Tower CCU and mounting hardware. A thorough structural analysis should be performed by a qualified engineer at your desired location prior to installation. Itron is not responsible for improper installations or for installations at a site that cannot adequately support the Tower CCU.
Chapter 3 Installing the CCU/Repeater Tower Installation Overview The Tower CCU 100 (TCU) installation differs significantly from other CCU 100 installation profiles in that the CCU 100 is installed within a cabinet enclosure at the base of a radio tower and all of the antennas are mounted remotely. The standard cabinet protects the hardware from adverse environmental conditions and provides easy access for servicing the CCU and its related components. The TCU box comes preassembled except for the CCU.
Tower Installation TCU Components 1 RF Filter 2 Battery 3 Surge protection devices (SPDs), receptacle, terminal blocks 4 CCU mounting plate 5 Roxtec™ block 6 Wiring diagram 7 Document holder 8 Air filters There are two air filters, one shown at (8) and another behind the fan (9).
Chapter 3 Installing the CCU/Repeater To assemble the Tower CCU 100 1. Attach CCU to CCU mounting plate. a. Insert the CCU mounting disc into the mounting plate keyhole. b. Slide the CCU down until you feel it click into place. 2. Connect cable from CCU to RF filter. 3. Connect ground wire to CCU. 4. (optional) Connect the Ethernet cable to the CCU and the top of the 10/100 BT SPD. Feed the external Ethernet cable through the Roxtec block and connect it to the bottom of the 10/100 BT SPD.
Tower Installation 5. Connect the battery to the connector on the battery door of the CCU. The battery door connection is only present on CCUs designed for TCU installations. 6. Feed the GPS and WAN (if required) antenna cables through the Roxtec block and connect them to the CCU. 7. Connect the power cable to the CCU. 8. See Attaching the Remote Antennas on page 18 for instructions on installing the antennas. 9. Connect power to the cabinet. See the wiring diagram on the inside of the cabinet door.
Chapter 3 Installing the CCU/Repeater AC Tower Installation Diagram 38 CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
Solar Powered Installation Solar Powered Installation All coaxial cable connections must be properly weather-proofed per industry standards unless otherwise specified. This includes any connections for the antennas and the CCU/Repeater. If the CCU/Repeater is installed indoors, only the connections located outside must be weather-proofed. Warning Before installing a CCU/Repeater, ensure that the selected location can support the weight of the CCU/Repeater, mounting hardware, solar panels, and batteries.
Chapter 3 Installing the CCU/Repeater Solar Wiring Diagram The diagram below illustrates how a solar panel system must be wired to connect to the CCU/Repeater. This enclosure is pre-wired. You are required to connect only the power and the ground. To assemble the Solar CCU 100 1. Mount the solar panels and battery box as described in the Installation, Operation, and Maintenance Manual supplied with the solar system. 2.
Solar Powered Installation Solar Installation Diagram The diagram below shows a typical solar powered installation.
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CHAPT ER 4 Battery Care and Replacement In this chapter, you will learn how to perform field maintenance on the CCU/Repeater battery. With some routine care, the batteries used by CCUs/Repeaters will perform at optimal levels for several years. The following sections show you how to store and charge spare CCU/Repeater batteries, as well as how to replace a CCU/Repeater battery in the field. Shipping Requirements Warning! Electrical fire hazard—protect against shorting.
Chapter 4 Battery Care and Replacement Battery Storage and Charging To ensure maximum lifespan and efficiency from your CCU/Repeater batteries, Itron recommends the following storage and maintenance procedures. Long-Term Storage Batteries may be stored for up to two years at room temperature (25°C or 77°F), and then may be recharged with no loss in cell reliability or performance capabilities.
Battery Storage and Charging State of Charge The state of charge (SOC) of the battery can be approximated by using the curve shown in the chart below. This curve is accurate to within 20% of the true SOC of the cell under consideration, if it has not been charged or discharged within the past 24 hours. The curve is accurate to within 5% if the cell has not seen any activity, charge or discharge, for the past five days.
Chapter 4 Battery Care and Replacement Battery Service Life All batteries have extremely variable service life, depending upon the type of cycle, environment, and charge to which the cell or battery is subjected during its life. There are two basic types of service life: cycle life and calendar life. The battery in the CCU/Repeater is called in to service only during power outages, so in this case only calendar (or float) life is applicable.
Replacing the Integrated Battery Replacing the Integrated Battery The following procedure shows you how to replace the integrated battery once it has been installed in the field. Warning Risk of explosion if battery is replaced by an incorrect type. Always replace with Itron part number BAT-0045-001. For information on battery disposal or recycling, contact EnerSys at 1.800.363.7797 or recycling@enersys.com. To replace the battery 1.
Chapter 4 Battery Care and Replacement 48 CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
AP PENDIX A Detailed CCU/Repeater Specifications CCU/Repeater Dimensions and Weight Weight is shown in pounds and dimensions are shown in inches. Component Weight CCU/Repeater 7 lbs AC tower unit 76 lbs Remote GPS/WAN antenna system 6 lbs Remote 900 MHz antenna system 3.
Appendix A Detailed CCU/Repeater Specifications Antenna Specifications - 100 Specifications for the standard (unity gain) endpoint antenna and high gain antenna are shown in the following table. Important All coaxial cable connections must be properly weather-proofed per industry standards unless otherwise specified. This includes any connections for the antennas and the CCU/Repeater components. If the CCU/Repeater is installed indoors, only the connections located outside need to be weather-proofed.
Environmental Specifications Environmental Specifications The following environmental specifications are associated with a CCU/Repeater. Specification Value Operating temperature Components GPS/WAN antenna system: -33° C to 60° C CCU/Repeater: -33° C to 60° C Storage temperature -40° C to 85° C Note Batteries may be stored for up to two years at 25° C without periodic recharging. When batteries are stored at this temperature, an open circuit voltage audit should be conducted every six months.
Appendix A Detailed CCU/Repeater Specifications Battery Pack The battery pack is contained in its own compartment. The battery pack is a three-cell, sealed, lead acid battery pack (6V, 4.5 amp-hours) that is field replaceable and designed to last five years under normal circumstances. To ensure minimal impact upon battery life, a preventative maintenance schedule of two year replacement is required in an extreme environment, such as a desert installation.
AP PENDIX B Status and Diagnostics Status Indicator The LED Status Indicator is primarily intended to support installation personnel for immediate feedback. The following sequences define the Fixed Network solution's operational characteristics: 1. Each status sequence is repeated at 20 second intervals. The following status indicators are enabled at power-up or upon a communication failure with endpoints or backhaul.
Appendix B Status and Diagnostics Diagnostic Port The wireless diagnostic port is based on the IEEE 802.11 LAN/MAN wireless specification. The 802.11 Wi-Fi interface has been exclusively designed to support system diagnostic capabilities and is intended to be available for field personnel use. • The diagnostic radio is available only at power up of the system or by the reception of a wake-up message that is received by the 900 MHz radio.
Performing an Antenna Sweep Test • CCU/Repeater status • Power source (AC or battery) • Battery state • Internal temperature • GPS status (number of satellites + GPS time and lat/lon position) • Firmware versions • • Hardware versions Event logs • Power outage logs • • WiFi access logs • High temp/Low temp alarms Configuration collection • TX power • Endpoint filtering settings • Configuration items settings • Firmware update interface • Force reboot Performing an Antenna Sweep Test If th
Appendix B Status and Diagnostics 56 CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
Index A I AC service requirements • 9 antenna placement • 9 antenna specifications • 50 antennas • 3, 5, 9, 10, 11, 18, 19, 50, 55 attaching the CCU/Repeater • 21 attaching the direct mount antenna • 19 attaching the remote antennas • 18 installation profiles • 7 installing the battery • 30 installing the CCU/Repeater • 17 B M battery • 44 battery pack • 52 battery storage • 44 brackets • 15, 21 mains powered installation • 12 maintenance • 43 materials not provided by Itron • 13 module • 2 mounting
Index solar installation diagram • 41 solar powered installation • 39 solar wiring diagram • 40 specifications • 49, 50, 51 state of charge • 45 status indicator • 53 storage • 44 T transmitter • 51 W wall mount • 26 WAN antenna • 3, 8, 10, 11, 18, 50, 55 WAN coverage • 8 58 CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
