T CCU4 Collector Field Installation and Service Guide D R A F T !
Identification CCU4 Collector Field Installation and Service Guide TDC-0359-000b 04/02 Trademark Notice Itron is a registered trademark of Itron, Inc. All other product names and logos in this manual are used for identification purposes only and may be trademarks or registered trademarks of their respective companies.
Contents List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix List of Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii How This Book is Organized . .
Measuring the Mounting Angle of a Pole or Davit. . . . . . . . . . . . . . . . . . . . . . .10 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Unpacking the CCU4 Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Packing Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 CDPD Version (part #CCU-4011-001) . . . . . . . . . . . . . . . . . . . .
Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Appendix B Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures Attaching a Davit to the Wood Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Attaching the CDPD Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Attaching the Collector to the Hanging Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Attaching the RF Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables AC Power Cable Wire Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDPD Modem Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDPD Version Packing List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Procedures Attach a Davit to a Wood Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Attach the CDPD Antenna to the New Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Attach the CDPD Antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Attach the Collector to the Hanging Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before You Begin This document describes the physical installation and maintenance of the CCU4 collector at the site of installation and presumes any pre-installation configurations or modifications have already been performed at the meter shop. For more information about procedures performed prior to installation, see the CCU4 Collector Configuration Guide.
Chapter 1 CCU4 Collector Overview Itron’s Cell Control Unit 4 (CCU4) collector is a self-contained device that collects energy consumption and tamper data from Itron Encoder Receiver Transmitters (ERTs) installed on commercial and residential utility meters, and then forwards this information over public networks to a central data collection site (the fixed network headend).
Fixed Network Diagram Fixed Network Diagram Figure 1 shows the role of the CCU4 collector in the overall fixed network. The collector reads and stores meter data from water, gas, and electric ERT endpoints. It then transmits this data via either POTS or the CDPD public network to the headend server.
CCU4 Collector Components CCU4 Collector Components The CCU4 collector’s modular design consists of a number of components fixed together to form a single weatherproof device. The rugged, adjustable mounting bracket secures the device in high winds and under heavy ice loads. Electrical components are designed into a plastic enclosure that provides double insulation and a high level of safety while handling the device.
CCU4 Collector Components Upper Housing The upper housing contains the public network interface modem and the external power and communications connectors. Each collector contains either a CDPD modem or a POTS (Plain Old Telephone Service) dial-up modem, but not both at the same time. The upper housing can be replaced to change the method of public network access.
CCU4 Collector Components Compact Flash Memory The compact flash memory is a solid state hard drive that stores the complete operating system and the collected data. It appears as a standard hard drive to the system. The compact flash memory two copies of the operating system, so the entire network can be switched to a new operating system at a scheduled time, but can still revert back to the earlier version if there is a problem with the new operating system.
CCU4 Collector Components 6 CCU4 Collector Field Installation and Service Guide TDC-0359-000b 04/02 DRAFT
Chapter 2 Installation Considerations ERT Compatibility The CCU4 collector reads the following types of Itron ERTs and messages: • 25 Series • 40 Series • 41 Series • 45 Series • 50W • SSD (Solid State Demand ERT) • SCM and IDM messages- IDM first priority Collector to ERT Ratio and Distance Although the CCU4 collector potentially can read many more ERTs, to ensure all data is collected, place one collector for every 100 unique ERTs.
Installing a Davit on a Wood Pole Installing a Davit on a Wood Pole The CCU4 collector is installed on the davit of a pole, which is the part of the pole that extends out, away from the pole and is parallel to the ground. A light pole has an existing davit that holds the light fixture, and the collector is installed about 6 in. behind the light fixture on the davit. Wood poles do not usually have davits, but you can install one on the pole with a davit kit.
Calculating Wind Load 7. Tighten the through-bolt and the lag bolt until the bracket is firmly attached to the pole and the end of the support arm is parallel to the ground. Figure 3: Attaching a Davit to the Wood Pole Davit Wood Pole Upsweep Arm Through-Bolt Lag Bolt Downsweep Arm Calculating Wind Load Wind load is the combination of maximum weight and Effective Projected Area (EPA) that the davit or pole can withstand.
RF Antenna Angle Example: Aluminum Light Pole Wind Load A G.E. Light Systems davit and pole support a maximum weight of 60 pounds and a maximum EPA of 1.5, rated at 100 MPHI (Miles Per Hour Isotach). The existing light fixture weighs 35 pounds and has a .7 EPA. The CCU4 collector (including mounting hardware) weighs 23 pounds and has a .7 EPA. The combined weight of the collector and the light fixture is 58 pounds. The combined EPA of the collector and the light fixture is 1.4.
Grounding Grounding The CCU4 collector does not require an earth ground connection because the unit is sealed and encased in plastic. Unpacking the CCU4 Collector Remove the CCU4 collector from its shipping container and verify the protective foam pieces are not severely damaged. If these pieces are damaged, and the collector has significant visible damage, it may not function correctly. Important The collector must remain protected at all times prior to installation.
Unpacking the CCU4 Collector Additional Required Parts In addition to the contents of the CCU4 container, you must have the Pole Mount Kit (part # CCU-4401-001, shipped separately), and one of the power cables (shipped separately) listed in the table below, depending on the type of installation.
Chapter 3 Installing the CCU4 Collector This installation involves attaching the CCU4 collector to either the davit (the arm holding the light fixture) of the light pole or to a davit that has been installed on a wood pole. In either case, a davit must already be available on which to install the collector. Once the collector is installed, you must supply it with power either from the photoelectric sensor of the street lamp or from the secondary power wires of the wood pole.
Installation Procedure Summary Installing the Hanging Plate The hanging plate attaches to the light pole davit with two brackets that have sharp teeth on the side that contacts the davit, keeping the hanging plate firmly in place. When replacing the collector with a new one, you can remove the old collector without removing the hanging plate, thus speeding the replacement and maintaining the general placement of the collector. To Install the Hanging Plate 1.
Installation Procedure Summary Attaching the Collector to the Hanging Plate The collector attaches to the hanging plate with four bolts inserted through the slots in the plate and into holes in four L-brackets on the collector. You can adjust the collector so the RF antenna is plumb by sliding the bolts up and down in the slots and tightening the bolts when the antenna is perpendicular to the horizon. To Attach the Collector to the Hanging Plate 1.
Installation Procedure Summary 4. To adjust the unit for plumb, place the bubble-level tool on a flat surface of the collector and, with one hand, tilt the unit until the bubble in the leveling tool is away from the wall. It is not necessary to center the bubble in the circle. Bubble away from wall If you do not have a bubble-level, adjust the unit so that the bottom is parallel with the ground.
Installation Procedure Summary 2. Press the antenna onto the connector and turn the antenna clockwise until it no longer turns and is firmly in place. Figure 7: Attaching the RF Antenna RF Antenna Connecting the Means of Transmitting to the Headend If you are installing the CDPD version, you must attach the CDPD antenna.
Installation Procedure Summary 2. Press the antenna onto the connector, and turn the antenna clockwise until it no longer turns and is firmly in place. Figure 8: Attaching the CDPD Antenna CDPD Antenna RF Antenna To Connect the POTS Cable 1. Determine the distance from the collector to the POTS port. 2. Cut the cable to the appropriate length, leaving enough cable for routing and slack. 3. Hard-wire the unterminated end of the cable to the POTS port. Refer to the table below to identify each wire.
Installation Procedure Summary 4. Run the other end of the cable to the communication port on the CCU4 collector. Wrap any excess cable around the davit or use tie wraps (not included) to secure the cable. 5. Connect the cable to the communications port on the collector. Figure 9: Connecting the POTS Cable To POTS Communications Port Installing the Battery Pack The battery pack ships uninstalled in the same container as the collector.
Installation Procedure Summary 5. While pressing the battery case into the battery compartment, finger-tighten the four captive-screws until the battery case is held in place. 6. Using the flathead screwdriver, tighten the four captive-screws until the battery case is firmly in place.
Installation Procedure Summary 2. If you did not already do so to verify power, remove the photoelectric sensor, and insert the power cable plug adapter into the socket. 3. Replace the photoelectric sensor, taking care to restore the sensor window to its original orientation. 4. Wrap any excess cable around the davit or use tie-wraps (not included) to secure the cable away from the unit. 5. Connect the other end of the power cable to the 5-pin power connector on the collector. 6.
Installation Procedure Summary To Connect the Collector to the Secondary Power Wires 1. At the power line, connect the unterminated end of the cable to the power source on the pole, as shown below. Consult the following table for definitions of the wires in the AC power cable.
Installation Procedure Summary Verifying the Collector is Operational Once the collector is installed and receiving power, it should appear onscreen at the headend. To verify the collector is receiving power and the software is operating correctly, you must call the headend and give the administrator the IP address and the number of the collector. If the administrator identifies the collector onscreen, the installation is complete. To Verify the Collector is Operational 1. Call the headend. 2.
Chapter 4 Servicing the CCU4 Collector Field Replaceable Parts The following maintenance procedures are the only ones you can perform in the field: • Replace an antenna • Replace the battery pack • Replace the collector Each procedure is described on the following pages. Replacing an Antenna The POTS modem version has only one antenna, the RF antenna that attaches to the collector bottom.
Field Replaceable Parts 3. Press the antenna onto the connector while turning the antenna clockwise until it no longer turns and is firmly in place.
Field Replaceable Parts Replacing the Battery Pack The power supply connected to the CCU4 collector charges the battery pack. The battery pack can power the collector for 4 hours after power is lost and should be replaced every 5 years. Once the new battery pack is installed, it must charge for 16 hours before it is fully powered. Required Hardware and Tools You need a flathead screwdriver to replace the battery pack. To Replace the Battery Pack 1.
Field Replaceable Parts Replacing the Collector Required Tools You need the following tools to replace the CCU4 collector: • 7/16-inch nut driver, wrench, or ratchet-wrench • Inch-pound torque wrench with 7/16-inch socket • Flathead screwdriver • Itron Bubble-level Installation Procedure Summary You must perform the following procedures to replace a CCU4 collector: 1. Remove the current collector. 2. Attach the new collector to the hanging plate. 3. Attach the RF antenna. 4.
Field Replaceable Parts 6. Using the flathead screwdriver, tighten the four captive-screws until the battery case is firmly in place. Battery Case Battery Pack 7. Disconnect the power cable from the 5-pin power connector on the collector. 8. Turn the RF antenna on the bottom of the collector counter-clockwise, and unscrew it from the N-connector. 9. Remove the means of communicating with the headend. This depends on which version of the collector you are removing.
Field Replaceable Parts • If you are removing the CDPD version (part # CCU-4011-001), turn the CDPD antenna on top of the collector counter-clockwise, and unscrew it from the N-connector. CDPD Antenna (part # CCU-4011-001 only) POTS Cable (part # CCU-4012-001 only) Power Cable RF Antenna 10. With one hand, hold the bottom of the collector. 11. With the other hand, use a 7/16-inch nut driver, wrench, or ratchet-wrench to remove the four bolts holding the collector to the hanging plate.
Field Replaceable Parts 12. Lower the collector down and away from the hanging plate, and set it aside. Figure 14: Collector Shown Detached from Hanging Plate Attaching the New Collector to the Hanging Plate To Attach the New Collector to the Hanging Plate 1. With one hand, hold the collector below the hanging plate and align the L-bracket holes on the unit with the slots on the hanging plate. 2. Insert each of the four 1/4-20 x 3/4-inch hex-head bolts through a slot and into an L-bracket hole. 3.
Field Replaceable Parts 4. To adjust the unit for plumb, place the bubble-level tool on a flat surface of the collector and, with one hand, tilt the unit until the bubble in the leveling tool is away from the wall. It is not necessary to center the bubble in the circle. Bubble away from wall If you do not have a bubble-level, adjust the unit so that the bottom is parallel with the ground.
Field Replaceable Parts Reconnecting the Means of Transmitting to the Headend If you are installing the CDPD modem version (part # CCU-4011-001), you must attach the CDPD antenna. If you are installing the POTS modem version (part # CCU-4012-001), you must reconnect the POTS cable. To Attach the CDPD Antenna to the New Collector 1. Insert the antenna through the hole in the top of the hanging plate and align it with the Nconnector on top of the unit. 2.
Field Replaceable Parts Verifying the New Collector is Operational Once the collector is installed and receiving power, it should appear onscreen at the headend. To verify the collector is receiving power and the software is operating correctly, you must call the headend and give the administrator the IP address and the number of the collector. If the administrator identifies the collector onscreen, the installation is complete. To Verify the New Collector is Operational 1. Call the headend. 2.
Appendix A CCU4 Collector Specifications Dimensions and Weight Figure 15: CCU4 Collector Dimensions 33.47 in. (85.01 cm) 7.80 in. (19.81 cm) 10.31 in. (26.19 cm) 10.31 in. (26.
Environmental Environmental Table 6: Environmental Specifications Specification Value Operating Temperature, component -40°C to +85°C (-40°F to + 185°F) Operating Temperature, battery -20°C to +60°C (-4°F to +140°F) Storage Temperature -40°C to +85°C (-40°F to + 185°F) Humidity Per MIL Standard 810 Solar Heat Load Exposure ? UV Stability ? Mechanical Vibration Per ANSI Standard C12 Paragraph 4.7.3.20. 5-350 Hz (with a sweep time of one octave per minute at .
Communications Connector Table 7: Power Specifications continued ... Specification Value Input Current 1.0 ARMS Inrush Power Conversion Efficiency ? Surge & Transient Immunity ? Battery Table 8: Battery Specifications Specification Value Type Four-cell sealed lead acid battery pack Power 8.8V, 2.
CDPD Modem CDPD Modem Table 10: CDPD Modem Specifications Specification Value Serial Interface (DTE) 19200 bps SLIP Interface RFC1055 AT-Command Interface Hayes Compatible with PCCA Wireless Extensions Power Supply Requirements +5 VDC ± 5% Transmitter Power Nominal 600 mW into 50 Ω CDPD Transmitting at Maximum Power 3.
POTS Cable POTS Cable Table 12: POTS Cable Wire Specifications Wire Color Signal Name Green Tip Red Ring Black Ground Yellow no connection Receiver Table 13: Receiver Specifications Specification Value Control Interface Serial (TTL levels) 38400 bps Command Interface Custom Itron API Power Supply Requirements +5.5 VDC ± 5%, +3.
Transmitter Transmitter Table 14: Transmitter Specifications Specification Value Control Interface Serial (I2C) Command Interface Custom Itron API Power Supply Requirements +5.5 VDC ± 5%, +8V to +10 VDC (PA) Transmit Power at Antenna Up to +36 dBm (4.
Appendix B Troubleshooting DRAFT Appendix B - Troubleshooting 41
Index C Conventions xiii DRAFT Index 43
