Intelis Gas Meter Installation Guide Technical Communications knowledge to shape your future
Identification Intelis Gas Meter Installation Guide 8 March 2019 TDC-1782-002 Copyright © 2018-2019 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 Chapter 1 Important Safety and Compliance Information.............................. 1 USA, FCC Part 15 spectrum compliance............................................................................................................. 1 Canada, ISED spectrum compliance....................................................................................................................2 RF Exposure (FCC/ISED).................................................................................................
Proving the Intelis Gas Meter using the Honeywell SNAP proving system............................................. 23 Tempering the meter by exercising...................................................................................................24 Setting up the prover........................................................................................................................ 25 Proving the Intelis Gas Meter.....................................................................................
Chapter 1 Important Safety and Compliance Information This section provides important information for your safety and product compliance. USA, FCC Part 15 spectrum compliance This device complies with Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. Operation is subject to the following two conditions: • This device may not cause harmful interference.
Important Safety and Compliance Information Canada, ISED spectrum compliance Compliance Statement Canada 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.
Important Safety and Compliance Information Electromagnetic compatibility Caution: Use only approved accessories with this equipment. All cables must be high quality, shielded, and correctly terminated. Unapproved modifications or operation beyond or in conflict with these use instructions may void the authority's authorization to operate the equipment. Intrinsic safety Warning: Substitution of components may impair intrinsic safety.
Important Safety and Compliance Information Electrostatic ignition hazard Warning: Verify the area is not hazardous when installing, servicing, cleaning, or touching the Itron device. Device cleaning Warning: Clean only with a damp cloth. Do not drop Warning: While Itron meters are designed to withstand a drop, dropping the meter may damage the device, impact the meter accuracy, and void the warranty.
Important Safety and Compliance Information Product notification Warning: These instructions are not intended to replace any utility or companyestablished meter installation procedures. These instructions are provided for additional information when the Intelis Gas Meter is installed. The meter installation must comply with all country, state, and local building and safety regulations as well as federal regulations including Section 192.353 of Title 49 of the Code of Federal Regulations.
Chapter 2 Intelis Gas Meter The Intelis Gas Meter is a solid state ultrasonic meter featuring an internal safety shut-off valve, built-in temperature conversion, and an integrated 500G communications module. The meter supports the listed functionality. • High flow alarm with optional automatic valve shutoff. • High temperature alarm and optional automatic valve shutoff. • Air detection. • Reverse flow detection. The Intelis Gas Meter can be configured for Mobile Mode or OpenWay Riva Network Mode.
Intelis Gas Meter Document Itron part number Field Deployment Manager Tools Application Guide TDC-1713-XXX Field Deployment Manager Field Representative's Guide TDC-1714-XXX Intelis Gas Meter models The Intelis Gas Meter is available in the listed types. • Temperature compensated • Non-temperature compensated Intelis Gas Meter components The Intelis Gas Meter features these components in a compact solid state meter.
Intelis Gas Meter • High temperature. Configuration for a high temperature event enables an automatic shut off if the high temperature threshold is reached or exceeded. Note: For more information about high flow and high temperature event configuration, see the FDM documentation. For document information, see Related documents on page 6. Integrated 500G communications module The integrated 500G RF communications module is designed to operate in either Mobile or OpenWay Riva Network Mode.
Intelis Gas Meter Specification Component materials Specification value Intrinsically safe For use in Class I, Division 1, Group D hazardous locations. Temp Code T1 -40°C ≤ Ta ≤ +70°C • UMU (ultrasonic measuring unit): polybutylene terephthalate (PBT) and polycarbonate (PC) • Valve plastics: PBT • Inlet and outlet tubes: polyoxymenthylene (POM) IECEx UL 18.0144X Ex ia IIA T1 Ga Regulatory FCC: Part 15.247, Part 15.
Intelis Gas Meter Specification Specification value ISM v3.6 (if using enhanced security) Itron Mobile v1.5 Mobile Collection v3.8.2 Standards Designed in compliance with ANSI B109.1, ANSIB109.0 (draft), and Measurement Canada PS-G-06 Intelis Gas Meter dimensions This section lists the Intelis Gas Meter dimensions. Dimensions are listed in Imperial and Metric units. A 8.4 inches 214.4 mm B 6.4 inches 161.9 mm C 6.0 inches 152.4 mm D 5.4 inches 138.3 mm E 3.1 inches 78.6 mm F 9.1 inches 230.
Chapter 3 Installing the Intelis Gas Meter This section provides the Intelis Gas Meter installation information. Warning: This product, as of the date of its manufacture, is designed and tested to conform to all governmental or industry safety standards then existing as they may apply to the manufacturer.
Installing the Intelis Gas Meter Prior to start-up Note: The Intelis Gas Meter is shipped from the factory with the shutoff valve in the open position. Verify the valve is open prior to installing the meter. Confirm the open valve icon is displayed on the LCD display and that the valve closed icon is not displaying . Perform a visual check of the inside of the meter outlet to also verify the shutoff valve is open.
Installing the Intelis Gas Meter Caution: Avoid high differential pressure across the meter. Abnormal differential pressures can damage internal meter components. 7. Alternate cracking open the upstream and downstream valves for a few seconds and then slowly-over a period of 10 seconds (¼ PSIG systems)-turn the valve to the ¼ open position and then to the full open position. 8. After the meter is pressurized, apply a soap solution or other good leak detecting liquid to the connections to check for leaks.
Installing the Intelis Gas Meter Installing the pipe plug 1. Clean any debris from the pipe plug and inspect it for any damage or deformation. Replace the pipe plug if any defects or wear are found. 2. Apply new sealant to the leading 3 to 4 threads of the pipe plug. Note: Itron recommends RectorSeal #5 sealant. 3. Using a 3/16" hand-driven Allen wrench, begin tightening the pipe plug into the threads, using care not to cross-thread or remove the sealant during the process. 4. Tighten the pipe plug.
Chapter 4 Intelis Gas Meter LCD Operation This section provides information about the Intelis Gas Meter LCD. The Intelis Gas Meter LCD This section describes the Intelis Gas Meter LCD menus that are displayed in a pre-defined order (1-8). Note: The Intelis Gas Meter ships in a sealed (locked) state. Additionally, there are two screens that display in response to an overflow or test condition.
Intelis Gas Meter LCD Operation LCD menu 2. LCD display Description Displays current index volume measured under an alarm condition. 3. Displays active alarms. Note: In the illustration, 001 indicates the number of the current displayed alarm while 003 indicates the total number of alarms. Before the display moves to the next menu page, all active alarms are displayed. If there are no alarms, NO ALARM displays.
Intelis Gas Meter LCD Operation LCD menu LCD display Description • E LF: Encoder Legal Fixed Firmware; UMU: Ultrasonic Measurement Unit CRC Intelis Gas Meter LCD display alarms The Intelis Gas Meter reports the following alarms on the LCD. Active alarms are logged. Events that create alarms are logged with a start and an end time. Users may cross check alarms over the network or with a device loaded with FDM Tools. For more information, see Cross checking Events with FDM.
Intelis Gas Meter LCD Operation LCD event or alarm Description propane peak shaving, for example, higher concentrations in propane or nitrogen can occur which are outside these reference gases. This can result in the speed of sound for the gas composition being closer to that of the speed of sound of air, which could result in a false indication of air detection.
Intelis Gas Meter LCD Operation LCD event or alarm Description Transducer error. The meter detected that its ultrasonic transducers experienced an error. This is an unrecoverable error. Important: If the Transducer Error remains active and does not clear, remove the meter and return it to Itron for evaluation. Additional LCD screen displays The LCD displays two additional screens in an overflow or test event. • Overflow. This screen displays if the meter reaches an overflow condition. • Display test.
Intelis Gas Meter LCD Operation Display icon Icon definition The meter is in Factory Ship Mode. Note: The truck icon clears when the Intelis Gas Meter is moved to an operational mode. Closed padlock icon. The meter is sealed. The lock icon clears when the meter is unsealed. Shutoff valve status icons The shutoff valve is open. The shutoff valve is closed. Shutoff valve is in armed state. The shutoff valve opening is actuated by pressing the button for 2 seconds and releasing it.
Chapter 5 Proving the Intelis Gas Meter This section provides information about proving the Intelis Gas Meter. Meteorological proving allows users to test the Intelis Gas Meter accuracy. Temper meters unpackaged in the proving area for 24 hours prior to the testing. Warning: Follow your company's standard operating procedures regarding the use of personal protection equipment (PPE). Adhere to guidelines issued by your company in addition to those contained in this document when proving meters.
Proving the Intelis Gas Meter Proving accessory Itron BPG SONICAL SN G6 pulse prover cable Intelis Gas Meter proving stand Itron part number CFG-7100-700 FIX-7100-001 Intelis Gas Meter Test Mode You must exit Test Mode to program Test Mode parameters. Attempting to program Test Mode parameters while the meter is in Test Mode will result in a temporary error. Test Mode configurable parameters include: • Pulse width. Default pulse width is 150 ms. • Pulse weight. Default pulse weight is 0.25 cf/pulse.
Proving the Intelis Gas Meter 1. The Intelis Gas Meter records the Test Mode consumption in the Test Mode index register. 2. The Intelis Gas Meter continues to output an optical pulse. Note: While the Intelis Gas Meter is in Test Mode, the LCD refresh rate is more frequent than when the meter is operating in Normal Mode. 3. The Intelis Gas Meter continues to update the normal volume registers.
Proving the Intelis Gas Meter Warning: Follow your company’s standard operating procedures regarding the use of personal protection equipment (PPE). Adhere to guidelines issued by your company in addition to those contained in this document when proving meters. Adjust the proving table to accommodate the height of the Intelis Gas Meter. If necessary, use the Intelis Gas Meter prover stand (Itron part number FIX-7100-001). Place the prover stand on the prover table and set the meter on the stand.
Proving the Intelis Gas Meter Setting up the prover 1. If you have not previously done so, log on to the prover. Note: If you are proving an Intelis Gas Meter for the first time on the prover or if you are changing proving parameters for the Intelis Gas Meter, you must log on as a Supervisor. To set up Itron Intelis Gas Meter and ITRON-RTY for the first time, follow steps 2 through 10. 2. Select Special Functions. 3. Select Edit Config Tables. 4. Select Edit Setup Values.
Proving the Intelis Gas Meter 5. Select the MeterMfg_Table checkbox. 6. Click in the next available (open) row in the top left table and enter ITRON-RTY for the meter manufacturer. Click off of the table and select Update Table.
Proving the Intelis Gas Meter Important: If Itron, Actaris, Sprague, or other is listed, it is still necessary to add a new manufacturer name specifically for the Intelis Gas Meter. Itron suggests using ITRONRTY following the steps listed below. The MFR Type must have the RTY suffix to allow setting and saving the revs desired for any given test and flow rate. Without the RTY suffix, the settings will not be saved. 7. Select Meter_Table checkbox.
Proving the Intelis Gas Meter • Other revs: 1 • Exercise revs: 1 • Revs unit volume: 4 • Jog rate: 50 • Max press diff: 0.5 • Miscellaneous customer-specific parameters as required (covered in Step 9) 9. Verify or enter the TOLERANCE values for POS, NEG, Slope, Repair, and Meter Size. These settings (values) are customer-specific. 10. Click off the table and select Update Table. 11. Select Exit, select Exit.
Proving the Intelis Gas Meter Proving the Intelis Gas Meter 1. Select Prove Meter. 2. Select the meter manufacturer (ITRON-RTY). 3. Select Intelis 250. 4. Select the correct mode for your meter (TC or NTC). Note: REG is equivalent to NTC. 5. Select the meter results mode (% error, % accuracy, % proof).
Proving the Intelis Gas Meter 6. Select the test mode (intest, outtest). 7. Select the optic test method (optic, mag). 8. Select the correct Index (volume per pulse) setting (Imperial, ¼ CF; Metric, 10 dm3).
Proving the Intelis Gas Meter Note: To reduce cycle time, contact the prover manufacturer to request a 0.10 CF per pulse option added. Testing has shown acceptable results with settings as low as 4 pulses on open and 1 on check but Itron recommends more pulses to obtain better results. 9. Click Select Meter to advance to the next screen. 10.
Proving the Intelis Gas Meter 11. Connect the Intelis Gas Meter end of the SNAP pulse prover cable to the Intelis Gas Meter optical port by firmly pressing the aluminum round threads of the cable into the port. Begin by positioning the cable at the 4:30 o'clock position. Tighten the cable to the 6:30 o'clock position. Note: The Intelis Gas Meter will automatically go into Test Mode (Menu 6) when the pulse prover output cable is connected. 12. Start the proving test by clicking RUN on the SNAP prover. 13.
Proving the Intelis Gas Meter Note: Proving the Intelis Gas Meter requires Measurement Systems prover software. See the Measurement Systems prover documentation for version requirements. Temper meters unpackaged and uncapped in the proving area for 24 hours prior to testing. If tempering is not possible, complete steps 1-8 of Temper the meter by exercising the meter on page 33. If the meters are tempered, continue to Setting up the Measurement Systems prover on page 34.
Proving the Intelis Gas Meter 4. From the Operate Valves and Observe Sensor Readings screen, press the 1 key or Chuck Valve to clamp the meter in place. 5. After the Intelis Gas Meter is clamped to the prover, turn on the appropriate nozzle in the center of the screen to exercise the meter. Note: Nozzle 6-250 is typically used for the Intelis Gas Meter. Exercise the meter for 10 to 15 minutes before proving the meter. 6. Close the nozzle. 7. Unclamp the meter by pressing the Chuck Valve button. 8.
Proving the Intelis Gas Meter 3. Select the Meter Model-1 tab. 4. Select the meter model. If the Intelis 250 or Intelis 250 TC are set up in the MMS prover, go to step 10. If the Intelis 250 or Intelis 250 TC is not listed, continue to step 5. 5. Select the Prover tab. Note: To access the Prover tab, you will be asked for a password. Contact Measurement Systems if you do not have a password. 6. Select Enter New Meter Model.
Proving the Intelis Gas Meter 7. Select an existing meter model similar to the new meter as a template. Itron recommends using the S-250 for an Intelis 250 gas meter and an S-250 TC for the Intelis 250 TC gas meter. Select the green bar on the bottom of the screen to use the selected meter as the starting point.
Proving the Intelis Gas Meter 9. Press Enter or click the blue bar at the bottom of the screen to go back to the meter setup menu. 10. Select the Exercise Cycle Duration. The Intelis Gas Meter Exercise Cycle Duration is typically 15 seconds. 11. Set Leak Test to Yes.
Proving the Intelis Gas Meter 12. Verify or enter Test Revs: Index Open, Check, Other settings. Itron recommended settings are listed. • Open: 6 • Check: 2 • Other: 0 Note: Testing has shown acceptable results with settings as low as 4 pulses on open and 1 on check but Itron recommends more pulses to obtain better results. 13. Select the Volume: Index setting. The Volume: Index setting is the recommended volume per pulse. Itron recommended settings are listed. • Imperial setting: 0.
Proving the Intelis Gas Meter • Check: 50 • Other: 125 Important: Required Open and Check flow rates may be different than those shown here. 15. Select the Proving Method: Index. The options are Index or Magnetic. 16. Select the mode for your meter. Available options are TC or NON-TC. 17. Select the Meter Model-2 tab.
Proving the Intelis Gas Meter 18. Verify or enter the InTest and OutTest limit values for Open Limits, Check Limits, Other Limits, and Delta Limit. The Open, Check, Other, and Delta Limit settings (values) are customer-specific. 19. Verify or enter the limit values for Check Dif Limits, Monitor Peaks?, and Max Peak. The Check Dif Limits, Monitor Peaks? and Max Peak settings (values) are customerspecific.
Proving the Intelis Gas Meter 20. Verify or enter Tangent Adjustment: Tangent Type. Note: The Tangent Adjustment: Tangent Type setting can be any non-blank value. The Tangent Adjustment: Tangent Type value is not used to prove the Intelis Gas Meter. 21. Select the Global tab and Display Method for your meter results. Display Method options are listed. • Error • Accuracy • Proof 22. Select InTest/OutTest. The options are InTest or OutTest.
Proving the Intelis Gas Meter 23. Press or click the green bar at the bottom of the screen to exit the Meter Setup Menu. Proving the Intelis Gas Meter 1. Connect the Measurement Systems pulse prover cable (Itron part number CFG-7100-500) to the port on the left side of the Measurement Systems prover. Note: If your Measurement Systems prover does not look like the illustration, contact Measurement Systems for an adapter cable to connect the Measurement Systems pulse prover cable to your prover.
Proving the Intelis Gas Meter 2. Connect the Intelis Gas Meter end of the Measurement Systems pulse prover cable to the Intelis Gas Meter by firmly pressing the aluminum round threads of the cable into the port. Begin by positioning the cable at the 4:30 o'clock position. Tighten the cable to the 6:30 o'clock position. Note: The Intelis Gas Meter automatically goes into Test Mode (Menu 6) after the cable is properly connected to the optical port. 3. Enter the Intelis Gas Meter serial number.
Proving the Intelis Gas Meter 4. Press or click the green bar on the bottom of the screen to begin the Measurement Systems proving test. 5. Verify the LED blinks (pulses) when the air begins to flow through the meter. Proving the Intelis Gas Meter using the Energy Economics (EEI) proving system This section provides the information to set up an Intelis Gas Meter using an EEI proving system. Note: Proving the Intelis Gas Meter requires Energy Economics prover software.
Proving the Intelis Gas Meter Note: Logging on to the EEI prover application requires maintenance level security. 2. Select Maintain > Sensor Maintenance. 3. Clamp the Intelis Gas Meter to the prover and turn on appropriate nozzles in the center column of the Sensor Maintenance window to exercise the meter. Note: Nozzle 192 CFH is typically used to exercise the Intelis Gas Meter. 4. Exercise the meter for 10 to 60 minutes until the Out Temp value does not vary by more than 0.2° F within a minute. 5.
Proving the Intelis Gas Meter 6. Unclamp the meter. 7. Exit the Sensor Maintenance window by clicking Done in the lower right corner of the window. Setting up the EEI prover 1. Log on to the EEI prover application. 2. Clamp the Intelis Gas Meter to the EEI prover. 3. Select the Meter tab and choose ITRON from the Manuf drop-down list. Important: If ITRON is not in the Manuf. drop-down list, contact EEI Prover Systems for help in adding ITRON to your EEI Systems Prover. 4.
Proving the Intelis Gas Meter 5. Click the Options tab. The Meter Information > Test Options window opens. 6. Select Eye for the Test Options Sensor.
Proving the Intelis Gas Meter 7. Select Open & Check for the Run Type Test Options. 8. Enter 100 for Flow > Open %.
Proving the Intelis Gas Meter Important: Required Open flow rates may be different than those shown here. 9. Enter 20 for Flow > Check %. Important: Required Check flow rates may be different than those shown here. 10. Select 1/10 cuft for Hand Size.
Proving the Intelis Gas Meter 11. Click Done to complete the Meter Information > Test Options and close the window. Note: All other settings (Tangents, Ultra Intest Lock, Ultra Adjust Lock and Station) on the Test Options window are not relevant for the Intelis meter Proving the Intelis Gas Meter 1. Connect the EEI pulse prover cable (Itron part number CFG-7100-400) to the EEI prover index eye connector.
Proving the Intelis Gas Meter 2. Connect the Intelis Gas Meter end of the EEI pulse prover cable to the Intelis Gas Meter by firmly pressing the aluminum round threads of the cable into the port. Begin by positioning the cable at the 4:30 o'clock position. Tighten the cable to the 6:30 o'clock position. Note: The Intelis Gas Meter automatically enters Test Mode when the pulse output cable is connected to the meter. 3. Press the EEI prover's green button to begin the proving test. 4.
Chapter 6 Adjusting the Intelis Gas Meter Calibration Intelis Gas Meters are calibrated at the factory prior to shipment. FDM is used if it is necessary to recalibrate the meter. For more information about calibrating the Intelis Gas Meter using FDM, see the FDM Field Service Representatives Guide. For documentation information, see Related documents on page 6. Sending new calibration values using FDM initiates the following calibration operations. 1. Run the meter on a prover. 2. Exit Test Mode. 3.
Adjusting the Intelis Gas Meter Calibration 4. Select Yes. 5. (Mobile endpoint mode only) If you are prompted to enter the Unlock ID, enter the Unlock ID.
Adjusting the Intelis Gas Meter Calibration 6. Select Next. The Parameters screen appears.
Adjusting the Intelis Gas Meter Calibration To demonstrate an example of adjusting the calibration, a sample prover station test results is displayed below and is provided as a reference. Use the following settings to adjust the meter calibration as it relates to your test results: • Prover station mode. Use the drop-down menu to select the % in which your prover station results are expressed: ◦ (Example selection) % Error ◦ % Accuracy ◦ % Proof • Prover flow rate unit.
Adjusting the Intelis Gas Meter Calibration 8. Select Next. A progress bar indicates that the meter's calibration is being adjusted.
Adjusting the Intelis Gas Meter Calibration The meter uses the entered values to calculate the required calibration parameters to a target of one of the following, depending on your selected prover station mode: • % Error. 0% open, 0% check • % Accuracy. 100% open, 100% check • % Proof. 100% open, 100% check 9. Click Quit or Finish to return to the Tools screen.
Adjusting the Intelis Gas Meter Calibration 10. (Recommended) Rerun the meter on the prover station to verify the meter calibration. It is expected that you see the results that match the following example: If the accuracy results are not as expected, repeat the calibration steps. Note: Prover station accuracy is estimated to be +/- 0.15-0.25%. To seal an Intelis gas meter 1. From the Tools menu, select OWR Intelis Gas Riva. 2. Select Test Mode Operations. 3. Select Seal Meter.
Adjusting the Intelis Gas Meter Calibration The Seal Meter Operation Successful screen indicates that the meter is sealed.
Adjusting the Intelis Gas Meter Calibration 4. Select Finish to return to the Tools screen. To unseal an Intelis gas meter's UMU 1. From the Tools menu, select OWR Intelis Gas Riva. 2. Enter the Endpoint ID. 3. Select the Endpoint Mode. • Mobile 4. Select Next. 5. Select Test Mode Operations. 6. Select the Utility ID. 7. Click Next. 8. Select Adjust Calibration for a device with a Seal State of Sealed. A warning message appears indicating that Adjusting Calibration will unseal the meter. 9. Select Yes.
Adjusting the Intelis Gas Meter Calibration a) Select Next. The Adjust Calibration screen appears. 11. Click Quit or Finish to return to the Tools screen.
Chapter 7 Intelis Gas Meter Index Replacement Warning: The Intelis Gas Meter index assembly is a static sensitive device. Avoid contact with the feed through connector pins on the index assembly. It is important to take ESD precautions when the index assembly is replaced. To ensure the Intelis Gas Meter retains consumption data, switch the Intelis Gas Meter to Factory Ship Mode prior to index replacement.
Intelis Gas Meter Index Replacement Component or tool Itron part number Phillips (size 1 or 2) slot-head (flat bladed sized 6-10 screwdriver) (Optional) Awl Hammer or mallet (Optional) Diagonal cutters Torque screwdriver (6-15 in-lbs) Phillips sizes 1-2 or slot-head sizes 6-10 Pre-Check Warning: Do not attempt to remove meter from gas pipes or adjust/modify/damage gas pipes/gas pipe connections in any way. Step replacement pictures do not show the gas pipes connected to the meter.
Intelis Gas Meter Index Replacement parts of the original index/meter/gas pipes. Do not use a power tool. Carefully pull the tamper seal out of the hole, hooking it with the tool if necessary. 3. There are two screws holding the original index onto the meter located behind the tamper seals just removed. Unscrew both screws while holding the original index. Do not discard the screws. 4. Firmly and slowly pull the original index straight away from the meter. 5.
Intelis Gas Meter Index Replacement Intelis Gas Meter Installation Guide TDC-1782-002 Proprietary and Confidential 65
