ChoiceConnect CCU 100 and Repeater 100 Installation Guide
Identification CCU 100 and Repeater 100 Installation Guide 25 August 2011 TDC-0971-xxx Copyright © 2010-2011 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.
Contents Before You Begin .......................................................................................................... v Documentation Conventions ............................................................................................................... v Related Documents ............................................................................................................................. v Chapter 1 CCU/Repeater Basics ...........................................................
Contents Chapter 3 Installing the CCU/Repeater ..................................................................... 17 Installation Overview .........................................................................................................................17 Attaching the External GPS/WAN Antennas .....................................................................................18 Attaching the Direct Mount 900 MHz Antenna ..........................................................................
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 vi CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
CHAPTER 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). • On a roof. 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; they may have either internal GPS/WAN antennas or external GPS/WAN antennas. The external CCU/Repeater configuration replaces the internal GPS/WAN antennas with external antenna connectors that allow both GPS and WAN antennas to be mounted externally. 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 The CCU shown below has connectors for the external GPS/WAN antennas. The component connections are described in the following table. 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. 2 900 MHz antenna This 900MHz antenna receives messages from and sends messages to endpoints and repeaters in the network.
Chapter 1 CCU/Repeater Basics Item 7 Description Ethernet Connects the CCU/Repeater to the Ethernet backhaul. Also used to connect the CCU/Repeater to a router for initial collector setup. Mating weatherproof cables are available from Itron. These cables are sealed industrial ethernet circular IP67 connectors (CONEC) Note A waterproof cap seals the Ethernet port from the elements in the field. Be sure to securely attach the cap once the collector is installed.
CCU/Repeater Components The external GPS/WAN antenna system is shown below. Item Description 1 External GPS antenna Receives GPS data from orbiting satellites. The cable connection on the bottom of this antenna is TNC Female. 2 Mounting bracket Attaches the antenna to your desired mounting location. 3 Antenna masts Provide support for the GPS and WAN antennas. Cables for each antenna are routed through the masts. Clamps on the front of the mounting bracket secure the masts.
Chapter 1 CCU/Repeater Basics Coaxial cable used to connect the 900 MHz antenna to the CCU/Receiver must be properly grounded. See Lightning Arrestor on page 12 for more information. 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.
CHAPTER 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.
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 external 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 Remote 900 MHz Antenna Placement Antenna placement is one of the most important factors in determining your overall system performance. Careful consideration must be given to proper antenna placement. Follow the general guidelines below when determining the ideal location for a remotemounted 900 MHz antenna. • The antenna must be mounted vertically.
Siting CCUs/Repeaters Grounding the Antenna System To minimize the potential for a lightning event, it is essential that remote/external antenna systems be properly grounded. Proper grounding prevents the accumulation of static charges on the antenna system and also provides a direct discharge to ground for any acquired charges. All grounding materials and procedures must meet or exceed local codes. Use coaxial grounding kits recommended by the coaxial cable manufacturer.
Chapter 2 Planning a CCU/Repeater Installation Lightning Arrestor A lightning arrestor (or surge protector) capable of withstanding multiple lightning strikes should be installed when using a remote/external antenna. This helps protect the CCU/Repeater in the event of a lightning strike. The lightning arrestor is fitted to the coaxial antenna cable at the SURGE end and the RF jumper cable that connects to the CCU/Repeater module at the PROTECTED end.
AC Mains Power AC Mains Power The AC mains wiring to the CCU/Repeater utilizes a three conductor cable. This cable can be terminated with either a NEMA L5-15 (125V, 15A) or a NEMA L6-15 (250V, 15A) locking plug in order to meet local electrical codes. The CCU should be powered by a dedicated 10A circuit. The CCU/Repeater should not be connected to a circuit protected by a GFCI breaker.
Chapter 2 Planning a CCU/Repeater Installation Remote Mount High Gain (8.15 dBi) 900 MHz Antenna on a Tower CCU The table below lists several options for coaxial cable that can be used with the remote mount high gain 900 MHz antenna. when installing the high gain antenna on a Tower CCU the FCC has set limits to the maximum transmit power of the CCU. In order to meet these limits, Tower CCUs with FCC ID number EO9CCU100T must have a minimum of 2.2 dB worth of loss (but not more than 3.
Materials Not Provided by Itron 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 62. 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.
Chapter 2 Planning a CCU/Repeater Installation 16 CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
CHAPTER 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 External GPS/WAN Antennas The external GPS and WAN antennas can be attached to pipes, poles, walls, and davit arms. A typical pole mount assembly is shown below. To attach the external GPS/WAN antennas 1. Assemble the antenna unit as described in the GPS/WAN Remote Antenna Mounting Kit Assembly Guide included with the GPS/WAN External Antenna Mounting Kit. 2. Attach the GPS/WAN antenna unit coaxial cable as described in "To connect cables" on page 29.
Attaching the Direct Mount 900 MHz Antenna Attaching the Direct Mount 900 MHz Antenna Attach the direct mount 900 MHz antenna before mounting the CCU/Repeater in its permanent location. To attach the direct mount 900 MHz antenna 1. Slide the black rubber boot onto the base of the antenna as shown in the following illustration. 2. Screw the antenna onto the top of the CCU/Repeater. Be careful not to cross-thread the connectors. Do not over-tighten.
Chapter 3 Installing the CCU/Repeater 3. Push the rubber boot as close as possible to the top of the CCU as shown in the following illustration. 4. Slide the antenna sleeve over the antenna, ensuring that the front of the antenna sleeve is to the front of the CCU/Repeater. 5. Using the included screws and 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. To mount the CCU/Repeater on a pipe 1. Using the two mounting brackets and four bolts, attach the mounting plate to the pipe. 2.
Attaching the CCU/Repeater 3. Insert the mounting disc into the mounting plate keyhole. 4. Using the provided set screws, secure the CCU to the mounting plate with the antenna 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. It may be necessary to use the remote 900 MHz antenna kit to achieve optimum RF performance and GPS coverage if the pole obstructs the desired RF path.
Attaching the CCU/Repeater To mount the CCU/Repeater on a pole 1. Attach the mounting disc to the back of the CCU with the included parts in the following order. CCU > mounting disk > flat washer > lock washer > bolt 2. Insert the mounting disc (on the back of the CCU) into the mounting plate keyhole. 3. Using the provided set screws, secure the CCU to the mounting plate with the antenna in the upright position. 4. 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. It may be necessary to use the remote 900 MHz antenna kit to achieve optimum RF performance and GPS coverage if mounted indoors or if the wall obstructs the desired RF path. To mount the CCU/Repeater on a wall 1.
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 3. Insert the mounting disc into the mounting plate keyhole. The following photos are shown off the davit arm for clarity. 4. Using the provided set screws, secure the CCU to the mounting plate with the antenna in the upright position.
Connecting Cables Connecting Cables Connect the remote/external 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 900 MHz antenna, attach the 900 MHz antenna cable to the connector on the top of the CCU/Repeater. This connection must be weatherproofed as described in the following steps. a. Attach the coaxial cable to the top of the CCU. b. Wrap vinyl electrical tape around the connection starting at the CCU and wrapping up the cable as shown in the following illustration.
Connecting Cables d. Wrap a layer of butyl rubber sealant over the vinyl electric tape. Ensure that the butyl rubber extends past the vinyl tape and onto the cable jacket. e. Overlap the butyl rubber so there is no gap. The butyl rubber will self-vulcanize over time and the seam will disappear. f. Wrap vinyl electric tape around the butyl rubber starting at the CCU and wrapping up as you did in step a.
Chapter 3 Installing the CCU/Repeater g. Continue wrapping the vinyl tape in a spiral back down to the CCU. You now have two layers of vinyl tape covering the butyl rubber. 4. If you are using an Ethernet backhaul, attach the Ethernet cable ensuring the weathertight connector is properly secured. If the Ethernet connection is not used, secure the weatherproof cap. 5. The grounding lug should be attached to earth ground according to local codes.
Installing the Battery To install the battery 1. Remove the battery cover by loosening the four screws securing it. These are captive screws and do not need to be fully removed from the battery cover. 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 To install a battery (ferrite bead) 1. Insert the battery connector into the connector on the CCU 100. 2. Align the edges of the ferrite bead with the edges of the recess in the battery well. 3. Press the ferrite bead into the recess in the battery well.
Providing Power 4. Place the battery in the battery well as shown in the following illustration. 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 the current configuration to be lost.
Chapter 3 Installing the CCU/Repeater AC 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.
Tower Installation Because of the size and weight of the Tower CCU, Itron recommends that more than one person be present for the installation. See Antenna Specifications on page 53 for more information. 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 externally and remotely.
Chapter 3 Installing the CCU/Repeater 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).
Tower Installation 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.
Chapter 3 Installing the CCU/Repeater 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. Instructions for using a Roxtec Block are supplied in the TCU cabinet.
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 External GPS/WAN Antennas on page 18 for instructions on installing the antennas. 9. Connect power to the cabinet.
Chapter 3 Installing the CCU/Repeater AC Tower Installation Diagram 42 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.
Solar Powered Installation 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. Wire the five conductor power cable to the solar cabinet, as shown in the Solar Wiring Diagram on page 44. Use the watertight grommet supplied with the solar cabinet. 3. Mount the CCU/Repeater in the desired location.
Chapter 3 Installing the CCU/Repeater Solar Installation Diagram The diagram below shows a typical solar powered installation.
CHAPTER 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 52 CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
APPENDIX 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 External GPS/WAN antenna system 6 lbs Remote 900 MHz antenna system 3.
Appendix A Detailed CCU/Repeater Specifications 54 CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
CCU/Repeater Dimensions and Weight The illustration below shows the dimensions for the optional pedestal unit. This unit ships with a gasket and fasteners to attach the cabinet to the pedestal.
Appendix A Detailed CCU/Repeater Specifications Antenna Specifications Specifications for the 900 MHz, GPS, and WAN antennas are shown in the following tables. 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.
Antenna Specifications GPS/WAN antennas Specification GPS WAN Part number MSE-0260-001 MSE-259-001 Gain 30 dB 0 dBd (806-896) 3dBd (1850-1990) Horizontal beamwidth Omnidirectional Omnidirectional Power rating N/A 100 W Impedance 50 ohms 50 ohms Termination Type TNC female Type N female Frequency 1575.42 MHz 806-896 MHz 1850-1990 MHz Polarization RHCP Vertical Prime power 3.3 V DC N/A Overall length 2.61 in. 13.75 in. Radome diameter 3.05 in. 1.310 in. Weight 6 oz. < 1.
Appendix A Detailed CCU/Repeater 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.
Battery Pack 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.
Appendix A Detailed CCU/Repeater Specifications 60 CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
APPENDIX B Status and Diagnostics Status Indicator The LED Status Indicator is primarily intended to support installation personnel for immediate feedback.
Appendix B Status and Diagnostics CCU State Description LED Pattern Ok The radio processor has booted and is reporting end-point messages to the host processor and the CCU has established an authenticated connection to the head-end. This condition will be signaled for about 15 minutes before moving the "low-visibility" state. Morse code for the letter sequence ‘BN’ ( _ . . . _ . ) The dit and dah timing described above with the space between the ‘B’ and the ‘N’ characters being 660 ms.
Index grounding • 1, 5, 11, 12, 13, 56 A I AC service requirements • 9 antenna placement • 10 antenna specifications • 56 antennas • 4, 5, 10, 11, 12, 18, 19, 56, 62 attaching the CCU/Repeater • 21 attaching the direct mount antenna • 19 attaching the remote antennas • 18 installation profiles • 7 installing the battery • 32 installing the CCU/Repeater • 17 L lightning arrestor • 12 long-term storage • 48 B battery • 34, 48 battery pack • 34, 59 battery storage • 48 brackets • 15, 21 M mains powered i
Index shipping requirements • 47 site selection • 8 siting • 8 solar installation diagram • 46 solar powered installation • 43 solar wiring diagram • 44 specifications • 53, 56, 58 state of charge • 49 status indicator • 61 storage • 48 T TCU mounting holes • 53 transmitter • 58 W wall mount • 26 WAN antenna • 4, 8, 11, 12, 18, 56, 62 WAN coverage • 8 weatherization • 29 64 CCU 100 and Repeater 100 Installation Guide Proprietary and Confidential
