Badger Meter ORION Series Installation guide

Brand: Badger Meter

Model: ORION Series

Type: Installation guide

ORION® Gas Endpoints

Integral Endpoint for American® Residential Gas Meters

ORI-UM-00909-EN-04 (July 2014)

Installation Manual

ORION® Gas Endpoints, Integral Endpoint for American® Residential Gas Meters

CONTENTS

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Questions Or Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Product Identication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Scope Of Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Product Unpacking And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

License Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation Tools And Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Label Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

American Gas Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Meter and Indexes Before Endpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Index Removal from an American Gas Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

American Meter Installation Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Assemble The Orion Endpoint And Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Endpoint Gaskets Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Place Four (4) Screws Into the Endpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Index Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Place Screws in Slotted Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Place Screws in Index With Holes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Drive Pawl Engagement and Index Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Place The Endpoint And Index On An American Gas Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Placing a Two-Feet Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Placing a One-Foot Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Place the Cover Over the Endpoint and Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Program The Endpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Programming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Insert Tamper Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installation Complete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Installation Manual

DISCLAIMER

The user/purchaser is expected to read and understand the information provided in this manual, follow any listed safety

precautions and instructions and keep this manual with the equipment for future reference.

Misuse, mishandling and/or inadequate maintenance may impair performance and/or compromise safety.

QUESTIONS OR SERVICE ASSISTANCE

If you have questions regarding the product or this document contact:

Badger Meter, Inc.

P.O. Box 245036

Milwaukee, WI 53224-9536

Telephone: (414) 355-0400, (800) 876-3837

Fax: (888) 371-5982

On the Web: www.badgermeter.com or call your local Badger Meter representative.

PRODUCT IDENTIFICATION

Record the product identification numbers from the nameplate.

Endpoint:

Model Number ________________________________________

Serial Number _________________________________________

Tag Number ___________________________________________

SCOPE OF MANUAL

This manual contains installation instructions for the Badger Meter ORION® and the Badger Meter ORION® Fixed Network

(SE) integral endpoint for American® Meter residential aluminum-case gas meters. Proper performance and reliability of the

ORION gas meter system depends upon installation in accordance with these instructions.

PRODUCT UNPACKING AND INSPECTION

OTE:N If damage to the shipping container is evident upon receipt, request the carrier to be present when the

product is unpacked.

Carefully open the shipping package, follow any instructions that may be marked on the exterior. Remove all cushioning

material surrounding the product and carefully lift the product from the package.

Retain the package and all packing material for possible use in reshipment or storage.

Visually inspect the product and applicable accessories for any physical damage such as scratches, loose or broken parts, or

any other sign of damage that may have occurred during shipment.

OTE:N If damage is found, request an inspection by the carrier’s agent within 48 hours of delivery and file a claim

with the carrier.

A claim for equipment damage in transit is the sole responsibility of the purchaser.

Page iii July 2014

ORION® Gas Endpoints, Integral Endpoint for American® Residential Gas Meters

LICENSE REQUIREMENTS

This device complies with Part 15 of FCC Rules. Operation of this device is subject to the following conditions: (1) This device

may not cause harmful interference, and (2) this device must accept any interference received, including interference that

may cause undesired operation.

IN ACCORDANCE WITH FCC REGULATIONS, “CODE OF FEDERAL REGULATIONS” TITLE 47, PART 2, SUBPART J, SECTION

1091, TRANSMITTERS (ENDPOINTS) PASS THE REQUIREMENTS PERTAINING TO RF RADIATION EXPOSURE. HOWEVER,

TO AVOID PUBLIC EXPOSURE IN EXCESS OF LIMITS FOR GENERAL POPULATION (UNCONTROLLED EXPOSURE), A 12 CM

DISTANCE BETWEEN THE TRANSMITTER (ENDPOINT) AND THE BODY OF THE USER MUST BE MAINTAINED

DURING TESTING.

No FCC license is required by a utility to operate an ORION meter reading system.

This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two

conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference

that may cause undesired operation of the device. Le présent appareil est conforme aux CNR d'Industrie Canada applicables

aux appareils radio exempts de licence. L'exploitation est autorisée aux deux conditions suivantes : (1) l'appareil ne doit pas

produire de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage

est susceptible d'en compromettre le fonctionnement.

Any changes made, but not approved by Badger Meter, can void the user’s authority to operate the equipment.

INSTALLATION TOOLS AND MATERIALS

Magnetized screwdrivers:

• 1/8" flat screwdriver

• 1/4” flat screwdriver

• #1 Phillips screwdriver

OTE:N If a battery powered driver is used, ensure torque maximums are not exceeded (usually 15 inch-pounds)

Putty knife or flat blade scraper

Badger Meter handheld programmer/data collector

LABEL INFORMATION

Certification markings are noted on the product label. Label markings include:

• Serial number and bar code plus product description

• FCC identification

• Certification markings

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Installation Manual

AMERICAN GAS METERS

Gas meter models: AL, AC, AT, AM, AR with suffixes: 175, 210, 225, 250, 310, 350, 425, 630

Meter and Indexes Before Endpoint

Odometer style index

Dial index

Figure 1: Gas meter and index styles

Index Removal from an American Gas Meter

1. Use a large screwdriver to puncture and remove tamper plugs, if present.

Tampter plug

Tamper plug

Figure 2: Tamper plug placement

2. Use a large screwdriver to remove and discard the four (4) mounting screws and the cover.

Figure 3: Remove mounting screws

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ORION® Gas Endpoints, Integral Endpoint for American® Residential Gas Meters

3. Completely remove and discard the old gasket. Use a putty knife to clean the meter surface of all gasket remnants that

might limit the eectiveness of the new gasket.

Figure 4: Remove gasket

4. Use a small screwdriver to remove the index. Discard the two (2) screws.

Figure 5: Remove index screws

Shown below is an American gas meter with the tamper plugs, index and gasket removed.

Figure 6: American gas meter without index

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Installation Manual

AMERICAN METER INSTALLATION MATERIALS

Rear gasket

Endpoint

4 screws

1/4-20 x 3/8”

Front gasket

Index from

existing meter

2 screws #8-16 x 1/2” or

2 screws #8-16 x 1/4”

4 screws

#8-16 x 1/2”

Cover

4 tamper plugs

ASSEMBLE THE ORION ENDPOINT AND INDEX

Endpoint Gaskets Attachment

The gaskets should be attached to the endpoint at the factory. If the gaskets are not attached:

1. Place the rear gasket on the back of the endpoint. Place the rear gasket so the tab is at the top of the endpoint, the drain

slots are pointing down, facing towards the gas meter. See Figure 7.

Tab on top

Drain slots pointing down

Drain slots towards gas meter

Figure 7: Rear gasket placement on endpoint

2. Place the front gasket on the other side of the endpoint.

a. Place the gasket so that its two holes go over the two protruding tines.

b. Be sure the notched end goes around the guide pin on the right side of the endpoint. See Figure 8.

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ORION® Gas Endpoints, Integral Endpoint for American® Residential Gas Meters

Notched end around guide

pin on right of endpoint

Holes over tines

Figure 8: Front gasket placement on endpoing

c. Be certain that the stepped edge is toward the endpoint boot and seated between the endpoint sealing face and the

alignment tabs.

Endpoint sealing face

Endpoint boot

Stepped edge

Alignment tabs

Figure 9: Stepped edge toward endpoint boot

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Installation Manual

Place Four (4) Screws Into the Endpoint

1. Place the four (4) ¼-20 X 3/8" screws through the endpoint and rear gasket from the front. See Figure 10.

Figure 10: Screw placement from front through endpoint and rear gasket

2. The screws are temporarily held in place by the rear gasket.

Drain slots towards down and

towards the gas meter

Gasket lip

Tab up

Screws held in place

Figure 11: Screws held in place by gasket

INDEX INSTALLATION

There are two (2) index capacities, ONE-FOOT and TWO-FEET; and two (2) index mounting styles, slots and holes.

Place Screws in Slotted Index

Place two (2) #8 X ½" self-tapping screws between the top metal dial and the lower plastic frame and into the holes on each

side of the index. See Figure 12.

2 screws

Figure 12: Self-tapping screw placement on slotted index

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ORION® Gas Endpoints, Integral Endpoint for American® Residential Gas Meters

Place Screws in Index With Holes

Place two (2) #8 X ¼" self-tapping screws between the dial and lower plate and into the holes on each side of the meter.

See Figure 13.

2 screws

Figure 13: Self-tapping screw placement on index with holes

Drive Pawl Engagement and Index Installation

1. Use care when handling the ORION endpoint and index to insure the endpoint rear drive pawl and the mating drive

pawls are not subjected to any physical abuse. Abuse may cause the spindles to become bent, misaligned or otherwise

inoperative.

When attaching an index to a ORION endpoint, make sure the index mounts securely to the endpoint. The front and rear

drive pawls must mate without causing any binding or potential for disengagement.

2. Align the two (2) screws in the endpoint holes. See Figure 14.

Figure 14: Align screws in endpoing holes

a. On a TWO-FEET dial, engage the index drive pawl into the half round connection in the endpoint. See Figure 15.

Index drive pawl

Half round connection

in endpoint

Figure 15: Drive pawl connection on two-feet dial

b. On a ONE-FOOT dial, place the index pawl hole into the pawl sticking out of the endpoint. See Figure 16.

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Installation Manual

Endpoint pawl

Hole in index pawl

Figure 16: Pawl placement on one-foot dial

3. Tighten the two (2) screws (6 inch-pounds max).

4. Test the drive pawl connection by turning the shaft on the rear of the endpoint several times. If dragging or friction is felt,

reposition the index to eliminate any drag. The dials should turn smoothly.

Figure 17: Testing the drive pawl connection

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ORION® Gas Endpoints, Integral Endpoint for American® Residential Gas Meters

PLACE THE ENDPOINT AND INDEX ON AN AMERICAN GAS METER

Verify that the rear gasket does not interfere with the endpoint drive shaft. Verify that the gasket fits around the semi-circular

cut out guide.

Rear gasket

Endpoint

drive shaft

Cut out guide

Figure 18: Endpoint and index placement

Placing a Two-Feet Dial

Align the rear endpoint drive pawl and the gas meter pawl. Place the four (4) ¼-20 X 3/8" endpoint screws against the holes in

the gas meter. See Figure 19.

Gas meter pawl

Endpoint pawl

Figure 19: Align endpoint drive pawl and gas meter pawl

Placing a One-Foot Index

Place the endpoint against the gas meter. Place the endpoint drive pawl so it is around the gas meter pawl. See Figure 20.

Gas meter pawl

Endpoint

pawl

Figure 20: Endpoint drive pawl placement around gas meter pawl

Tighten the four (4) endpoint screws (20 inch-pounds max).

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Installation Manual

Figure 21: Tighten endpoint screws

Move the TWO-FEET or ONE-FOOT dial back and forth to verify pawl connections. See Figure 22.

Figure 22: Verify pawl connections

Place the Cover Over the Endpoint and Index

1. Verify the front gasket is set properly.

Figure 23: Verify gasket is set properly

2. Place the cover on the gas meter and tighten it with the four (4) remaining screws (15 inch-pounds max).

Figure 24: Cover placement on meter

The endpoint unit is now ready for programming.

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ORION® Gas Endpoints, Integral Endpoint for American® Residential Gas Meters

PROGRAM THE ENDPOINT

Badger Meter uses a handheld programmer/data collector system to process and display screens.

Figure 25: Sample handheld, IR read head and cable

Please reference the Programming Guide for ORION gas endpoints and the manual for the handheld system.

Programming Procedure

To program the endpoint, position the handheld optic read head with the endpoint IR port.

Endpoint IR port

Figure 26: Endpoint IR port

Align the IR port of the handheld optic read head with the endpoint IR port.

Figure 27: Line up the handheld IR port with the endpoint IR port

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Installation Manual

INSERT TAMPER PLUGS

After programming the endpoint is complete and for security purposes, insert the four (4) red tamper plugs (supplied) in the

screw holes and push them in.

Tamper plug

Figure 28: Replace tamper plugs

INSTALLATION COMPLETE

Installation of the ORION endpoint for an American residential gas meter with dial or odometer index is now complete.

Figure 29: Completed installation

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www.badgermeter.com

MAKING WATER VISIBLE and ORION are registered trademarks of Badger Meter, Inc. Other trademarks appearing in this document are the property of their respective entities.

Due to continuous research, product improvements and enhancements, Badger Meter reserves the right to change product or system specications without notice, except to the