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2015001
User Manual
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Aclara 2015001 User Manual

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Series 4000 MTU
Maintenance
and Operation
Manual
Y20456-TUM
Rev. A
www.Aclara.com
Proprietary Notice
Information contained in this document is private to Aclara Technologies LLC, an Ohio limited liability company (Aclara). This information may not be published, reproduced, or otherwise disseminated without the express written authorization of Aclara.
Any software or firmware described in this document is furnished under a license and may be
used or copied only in accordance with the terms of such license.
Disclaimer
The information in this document is subject to change without notice and should not be construed
as a commitment by Aclara. Aclara assumes no responsibility for any errors that may appear in this document.
No responsibility is assumed for the use or reliability of software on equipment that is not supplied by Aclara.
TWACS, STAR, and Metrum Cellular are registered trademarks of Aclara Technologies LLC.
Aclara Technologies LLC
Confidential and Proprietary
Copyright 2015. All Rights Reserved.
Series 4000 Maintenance and Operations Manual (Y20456-TUM Rev A)

WARNINGS, CAUTIONS, AND NOTES

Always consult and adhere to all local and national safety codes, regulations, and standards.WARNING, CAUTION and Note statements are used throughout this manual to emphasize important and critical information to help you ensure safety and prevent product damage.These statements are defined below.
WARNING
CAUTION
NOTE
indicates a potentially hazardous situation which, if not avoided, could result in death or serious physical injury.
indicates a situation, which, if not avoided, could result in damage to equipment, damage to software, loss of data or invalid results.
indicates important supplemental information.
FCC/IC Compliance
The following statements cover the RF exposure guide and the field calibration procedure.
FCC/IC RF Exposure Guide
Field Calibration Procedure
Series 4000 Maintenance and Operations Manual iii
Aclara Technologies LLC low power RF devices and their antennas must be fixed-mounted on indoor or outdoor permanent structure(s) providing a separation distance of at least 20 cm from all persons during normal operation. This device is not designed (and it has no external connection) to operate in conjunction with any other antennas or transmitters. No other operating instructions for satisfying RF exposure compliance are needed.
Aclara Technologies LLC low power RF devices have passed through extensive testing and calibration procedures while in the factory. Therefore, no additional calibration or adjustment is required in the field.
Conformité FCC/IC

AVERTISSEMENTS, MISES EN GARDE ET REMARQUES

Toujours consulter et respecter les codes, règlements et normes de sécurité locaux et nationaux. Des AVERTISSEMENTS, MISES EN GARDE et remarques sont utilisés tout au long de ce guide pour souligner l'information importante et critique qui vous aidera à assurer la sécurité et à prévenir les dommages au produit. Ces énoncés sont définis ci-dessous.
AVERTISSEMENT
indique une situation potentiellement dangereuse qui, si elle n'était pas évitée, pourrait entraîner la mort ou des blessures graves.
MISE EN GARDE
indique une situation qui, si elle n'était pas évitée, pourrait entraîner des dommages à l'équipement, des dommages au logiciel, des pertes de données ou des résultats invalides.
REMARQUE
indique des informations supplémentaires importantes.
Conformité FCC/IC
Les énoncés qui suivent portent sur le guide d'exposition aux RF et la procédure de calibration sur place.
Guide d'exposition aux RF FCC/IC
Les appareils RF à faible puissance Aclara Technologies LLC ainsi que leurs antennes doivent être montés de manière fixe sur des structures intérieures ou extérieures permanentes qui se trouvent à au moins 20 cm des personnes pendant le fonctionnement normal. Cet appareil n'est pas conçu (et il n'a aucun branchement externe) pour être utilisé en association avec toute autre antenne ou tout transmetteur. Aucune autre instruction d'utilisation n'est requise pour assurer la conformité aux règles d'exposition aux RF.
Procédure de calibration sur place
Les appareils RF à faible puissance Aclara Technologies LLC ont été soumis à des tests étendus et multi-tâches et à des procédures de calibration complexes en usine. Par conséquent, ils ne requièrent pas de calibration ni d'ajustement supplémentaire sur place. Les appareils RF à faible puissance Aclara Technologies LLC sont expédiés au client dans des boîtiers scellés. Aucun ajustement ne peut donc être effectué sur place sans briser le boîtier scellé en usine.
iv Series 4000 Maintenance and Operations Manual
Table of Contents
Chapter 1: STAR Network Overview 1
Two-Way Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MTU/DCU Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DCU/NCC Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2: Series 4000 Operation 3
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Read Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Time Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Data Encryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Trend Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Read Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transmit Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 3: STAR Programmer Software 7
USB Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Communication LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Application Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
XML File Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Read MTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Turn Off MTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Add MTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replace MTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install Confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replace Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 4: Hardware Installation 23
Wall Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Solid Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hollow Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pipe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Conduit & Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MTU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Instrument Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chapter 5: Maintenance 35
Series 4000 Maintenance and Operations Manual v

STAR NETWORK OVERVIEW

The STAR Network is a fixed-network, Advanced Metering Infrastructure (AMI) that automatically reads water and gas instruments. The STAR Network uses a 3-tier configuration to read and transmit information between the measuring instrument and the utility office. The three tiers of the STAR Network are:
1. Meter Transmission Units (MTUs)
2. Data Collection Units (DCUs)
3. Network Control Computer (NCC)

Two-Way Communications

The STAR Network two-way advanced metering infrastructure (AMI) system allows encrypted data communications over secure, FCC licensed radio frequencies. This wireless fixed network consists of the Meter Transmitter Unit (MTU), Data Collector Unit (DCU), and Network Control Computer (NCC). Communications between the MTU, DCU, and NCC are explained in greater detail below.

MTU/DCU Communications

DCU/NCC Communications

Series 4000 Maintenance and Operations Manual 1
MTU/DCU communications occur on two FCC licensed (450-470 MHz) frequency channels. Configuration settings, on-demand requests, and Time Sync messages are sent from the DCU to the MTU. Instrument measurement and configuration readings and Time Sync requests are sent from the MTU to nearby DCUs.
DCU/NCC communications are conducted over TCP/IP protocols via the cellular, Ethernet, or Wi-Fi with the NCC. Configuration changes, on-demand requests, and Time Sync messages originate in the NCC and are sent to the MTU via the DCU.
™
backhaul. The DCU initiates and maintains communications
Two-Way Communications
2 Series 4000 Maintenance and Operations Manual

SERIES 4000 OPERATION

The Series 4000 MTU is designed to connect with a Honeywell ERX pressure monitor, a Honeywell Mini-AT volume corrector, or a Mini-Max volume corrector. In addition to a 10 item audit trail, the Series 4000 allows the user to perform on-demand reads and reconfigure the instrument and the MTU via the NCC. It contains a replaceable battery, two LEDs, and a USB port used for commissioning and reading information from the MTU locally.
The Series 4000 MTU is mounted to a wall or a pipe near the volume corrector or pressure monitor. The MTU connects to the instrument via cable and communicates with the DCU using FCC licensed frequencies.

Configuration

The Series 4000 MTU allows the user to change instrument configuration settings from the NCC. The MTU checks the instrument configuration daily, and returns the changed parameter and the new value to the NCC in a daily Change Report. The NCC will then compare the Change Report data to the initial configuration value transmitted to the NCC immediately after installation. In addition to these Change Reports, the user can also configure the MTU to send a full Configuration Report to the NCC every 30, 60, 90, or 180 days.
For added security, if there is an attempt to change the configuration settings through the MTU USB port, the MTU will notify the NCC within 25 hours.

Read Intervals

The rate at which the MTU reads data from the instrument is configurable to support instrument log intervals of 15 minutes or more. At the end of each interval, the MTU will read the instrument. The data will then be transmitted back to the NCC at an interval that is equal to the instrument log interval.

Time Synchronization

Time keeping is crucial for accurate reporting. The Series 4000 MTU and the NCC software are designed to ensure that the internal clocks of the instrument, MTU, and NCC all remain synchronized. In addition to synchronizing the time at initial installation, the MTU checks the instrument clock daily. If the clock is off by more than 10 seconds, it will automatically synchronize the instrument clock.
The MTU will send a flag to the NCC along with the amount of adjustment made to the instrument clock for any readings that are off by more than two minutes. When the NCC receives readings that are flagged with incorrect time, it will automatically correct the time stamps according to the difference reported by the MTU.
MTU Installation Requirements 3

Security

Security

Hardware

The 4000 Series MTU provides options for both hardware and software security.
The Series 4000 MTU enclosure is designed to allow the user to secure the door with a lockout device.

Software

The MTU may be configured to send the following tamper alarms to the NCC:
1. Interface tamper (configuration change via USB port)
2. Cut serial communication wire
Each tamper condition generates a corresponding alarm transmission that can be viewed in the NCC when viewing the Premise transmissions.
The MTU can be programmed to transmit an alarm for any of these tamper conditions. In the case of a tamper condition alarm, the unit will transmit an alarm message every minute for a given number of times (with a default of 3). When the tamper condition is no longer present, the alarm flag is cleared. Each time the tamper condition is detected, the unit will trigger an alarm.
4 MTU Installation Requirements

Alarms

In addition to the tamper alarms, the MTU may also be configured to send the following alarms to the NCC:

Last Gasp

The MTU will regularly report battery voltage values to the NCC. When this value falls below a specified value, the NCC will display a Low Battery notification. Aclara recommends changing the battery promptly when a low battery alarm is received. Please see Maintenance on page 35 for more information.

Pressure

The user can configure the MTU to return a pressure alarm whenever the pressure reading from the instrument is outside a given range. If enabled, the MTU will also begin operating in Trend Mode until the pressure returns to the desired range. Please refer to Trend Mode on page 5 for more information.

Serial Communication Problems

Series 4000 Operation
The MTU will return an alarm to the NCC if basic communication with the instrument is not possible. This will most likely be due to incorrect instrument configuration.

Data Encryption

The Series 4000 MTU units support the encryption of user sensitive data. When data encryption is enabled, all readings and data packets except for alarms will be encrypted prior to transmission.

Trend Mode

Trend Mode is an operating mode of the MTU that, when enabled, will begin automatically sending pressure values (and corresponding time stamps) at regular intervals whenever a pressure or other configured alarm is received from the instrument.
Trend Mode may also be initiated or canceled directly from the NCC. Using the default settings for Trend Mode, the MTU will record the pressure once a minute and transmit these readings once every six minutes to the NCC.

Read Interval

MTU Installation Requirements 5
The user may configure Trend Mode to read the pressure either once a minute or once every five minutes.
Trend Mode

Transmit Interval

The transmit interval for Trend Mode is pre-configured at six times the read interval. That is:
• If a 1 minute read interval is selected, the transmit interval will be 6 minutes.
• If a 5 minute read interval is selected, the transmit interval will be 30 minutes. If Trend Mode is canceled from the NCC or if the MTU receives a clear pressure
alarm signal from the instrument, the MTU will notify the NCC that only six more readings will be received in Trend Mode. The MTU will read and transmit the remaining Trend Mode reads, before it switches back to normal operating mode.
If Trend Mode is initiated manually via the NCC, it will continue for a maximum of 30 minutes if it is not manually canceled from the NCC.
Trend Mode data is recorded and stored along with graphical representations in the NCC for up to 13 months.
6 MTU Installation Requirements

STAR PROGRAMMER SOFTWARE

The STAR Programmer application is used along with a suitable tablet or laptop and a USB cable (Aclara part number 070-1700) to commission an MTU after installation or to turn an MTU off prior to storage or relocation. This section provides information on the USB communication interface and how to interact with the MTU using this application.

USB Port

The Series 4000 MTU uses a standard USB Type B port that allows for communication with a laptop or tablet running the STAR Programmer software.
WARNING: EXPLOSION HAZARD - BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO
AVERTISSEMENT:
Series 4000 Maintenance and Operations Manual 7
BE NON-HAZARDOUS
RISQUE D'EXPLOSION
L’EMPLACEMENT EST DÉSIGNÉ NON DANGEREUX AVANT DE CHANGER LA BATTERIE.
- AFIN D’ÉVITER OUT RISQU D’EXPLOSION, S’ASURER QUE
USB Port

Communication LEDs.

Two LEDs located to the right of the battery and above the COMP1 connector indicate the direction of communication through the USB port.
• The left LED (LED 1) indicates when data is sent from the tablet or laptop through the USB port to the Series 4000 MTU.
• The right LED (LED2) indicates when data is sent from the MTU out through the USB port to the tablet or laptop.
8 Series 4000 Maintenance and Operations Manual
STAR Programmer Software

Software

The STAR Programmer application may be used to commission an MTU after installation, read and troubleshoot an MTU in the field, or to turn off an MTU if it will not be in use for an extended period of time. Actions performed using the STAR Programmer software are logged and uploaded to the Network Control Computer (NCC) for verification at the end of each shift.

Prerequisites

The STAR Programmer application requires the following to communicate with a Series 4000 MTU:
Tablet or laptop with
• Windows® 7
• > 1.5 GHz
• > 2 GB RAM
• > 80 GB HDD
• Open USB port
USB-A to USB-B cable (Aclara #070-1700)
Series 4000 Maintenance and Operations Manual 9
Software

Application Installation

Use the following procedure to install the STAR Programmer software on a suitable tablet or laptop.
1) Double-click the STARProgrammerPC.msi file.
2) Click Next to begin the STAR Programmer Setup Wizard.
10 Series 4000 Maintenance and Operations Manual
3) Verify the installation location, and click Next.
STAR Programmer Software
4) Click Next to initiate the installation.
Series 4000 Maintenance and Operations Manual 11
Software
5) Wait while the STAR Programmer is installed.
6) Click Close after the Installation Complete confirmation appears.
12 Series 4000 Maintenance and Operations Manual
STAR Programmer Software

XML File Installation

Use the following procedure to install the XML files that accompany the STAR Programmer application.
1) Refer to the table below when selecting the appropriate STARXML.msi file for the
installation.
N
OTE: Multiple STARXML installations cannot coexist on the same machine.
Installation Type .MSI File
PC Interactive Mode - With Encryption STARXMLPCTEST.msi PC Interactive Mode - Without Encryption STARXMLPCTESTNONENCRYPT.msi PC Scripted Mode STARXMLPC.msi
2) Double-click the appropriate .msi file.
3) Click Next to begin the XML File Setup Wizard.
Series 4000 Maintenance and Operations Manual 13
Software
4) Verify the installation location, and click Next.
5) Click Next to initiate the installation.
14 Series 4000 Maintenance and Operations Manual
6) Wait while the XML files are installed.
STAR Programmer Software
7) Click Close after the Installation Complete confirmation appears.
Series 4000 Maintenance and Operations Manual 15
Software

Connection

Use the following procedure to connect a tablet or laptop to a Series 4000 MTU and open the STAR Programmer application.
1) Remove any security hardware from the
MTU door.
2) Open the door of the MTU.
4) Connect the remaining end of the USB
cable to the Series 4000 MTU.
5) Open the STAR Programmer application.
3) Connect the USB cable to the laptop or
tablet.
6) Leave the Operator and Password fields
blank and click
16 Series 4000 Maintenance and Operations Manual
Submit.
STAR Programmer Software

Operation

The STAR Programmer menu functions for Series 4000 MTUs are Read MTU, Turn Off MTU, Add MTU, Install Confirmation, and Replace Battery. Each of these functions are described in the following sections.
Read MTU
This option allows the user to read information from the MTU and the instrument. It will also write configuration settings to the instrument. Select this option to see the current MTU settings or after changing a battery that has completely lost power. When the user selects the Read MTU option:
1) Select Read MTU.
2) Wait while the STAR Programmer reads
the MTU.
3) After viewing the MTU information screen,
select the Main Menu.
OK to log the activity and return to
not
Turn Off MTU
This option allows the user to deactivate and turn off a previously commissioned MTU. When a Series 4000 MTU has been turned off, the STAR Programmer software will read the MTU Type, firmware version, and MTU ID before turning off the MTU. The MTU will cease all RF transmission and will only respond to commands sent through the USB port.
1) Select Turn Off MTU.
2) Wait while the application reads and turns
off the MTU.
3) Click OK to log the activity and return to the
Main Menu.
Series 4000 Maintenance and Operations Manual 17
Software
Add MTU
Select this option to commission a new MTU or an MTU that was turned off.
1) Select Add MTU.
3) Enter the 10-digit Account Number into the
Gas Network Node (
4) Verify the Instrument Type field has
auto-populated, and click
GNN) field.
OK.
2) Click OK to read the MTU and instrument.
5) Wait while the software commissions the
MTU. This may take several minutes.
18 Series 4000 Maintenance and Operations Manual
STAR Programmer Software
6) Once commissioning is complete, the
software will return the current values allowing you to confirm the settings.
7) Click OK to confirm the log entry and return
to the Main Menu.
8) To close the STAR Programmer application,
select File > Exit.
Series 4000 Maintenance and Operations Manual 19
Software
Replace MTU
To replace an existing MTU or after installing a new battery in an MTU that has been without power for an extended amount of time, use the Replace MTU option in the STAR Programmer application.
1) Select Replace MTU.
3) Enter the 10-digit Account Number into the
Gas Network Node (
4) Verify the Instrument Type field has
auto-populated, and click
GNN) field.
OK.
2) Click OK to read the MTU and instrument.
5) Wait while the software commissions the
MTU. This may take several minutes.
20 Series 4000 Maintenance and Operations Manual
STAR Programmer Software
6) Once commissioning is complete, the
software will return the current values allowing you to confirm the settings.
7) Click OK to confirm the log entry and return
to the Main Menu.
8) To close the STAR Programmer application,
select File > Exit.
Series 4000 Maintenance and Operations Manual 21
Software
Install Confirmation
This option allows the user to confirm that the MTU can communicate with the available DCUs and to see information about the MTU, DCU, and the communication between the two.
1) Select Install Confirmation.
Replace Battery
Use the following procedure after replacing the battery in the MTU.
1) Select Replace Battery.
2) Click OK to initiate the confirmation
process.
3) Wait while the STAR Programmer reads
the MTU.
4) After viewing the MTU information screen,
select the Main Menu.
OK to log the activity and return to
2) Click the OK button to initiate the process.
3) Wait while the STAR Programmer reads
the MTU.
4) Click OK to log the activity and return to the
Main Menu.
22 Series 4000 Maintenance and Operations Manual

HARDWARE INSTALLATION

Aclara offers kits to mount the Series 4000 MTU to a wall or to a pipe with an outside diameter of 2
"- 3". Use the corresponding instructions to mount a Series 4000 MTU using one of these kits.
NOTE In addition to the mounting hardware, the installation kits also include one 10' length of
conduit, two conduit fittings, one 12' length of five conductor cable, and one 12’ length of two conductor cable. Please refer to the Wiring section on page 29 for installation procedures for these items.

Wall Mount

Wall Kit #109-2015-001M-020
Item Description Application Quantity
A ¼ x 2" Stainless steel wedge bolt Solid walls 4 B ¼" Stainless steel flat washer Solid and hollow walls 4
C ¼ - 20 x 2½" Stainless steel bolt Hollow walls 4 D Wall anchor Hollow walls 4
Series 4000 Maintenance and Operations Manual 23
Wall Mount

Solid Wall

Follow this procedure to mount the MTU to a solid wall.
Special Tools
In addition to standard tools and safety equipment, you will need the following tools to mount the MTU to a solid wall:
• Drill
• ¼" Wedge drill bit
• 0-35 ft-lb Torque-limiting wrench
Instructions
1) Determine the appropriate mounting
location for the MTU. Keep RF signal propagation in mind when choosing a location.
2) Position the MTU against the wall at the
desired location and mark locations for the four bolt holes.
3) Drill holes at the four marked locations
with a ¼" Wedge Bit.
4) Insert a wedge bolt through a flat washer
and one of the mounting holes on the MTU.
5) Thread the bolt partially into the
appropriate hole drilled in step 3.
24 Series 4000 Maintenance and Operations Manual
6) Repeat steps 4 and 5 for the remaining
bolts.
7) Tighten all four wedge bolts to 27-33 ft-lb.
Hardware Installation

Hollow Wall

Follow this procedure to mount the MTU to a hollow wall.
Special Tools
In addition to standard hand tools and safety equipment, you will need the following tools to mount the MTU to a hollow wall:
• Drill
• ½" Drill bit
• 0-10 ft-lb Torque-limiting wrench
Instructions
1) Determine the appropriate mounting
location for the MTU. Keep RF signal propagation in mind when choosing the location.
2) Position the MTU against the wall at the
desired location and mark locations for the four bolt holes.
3) Drill holes at the four marked locations
with a ½" drill bit.
4) Insert the anchor end of one wall anchor
through one of the drilled holes.
Series 4000 Maintenance and Operations Manual 25
5) Pull the anchor until it is tight against the
back side of the wall surface. Then slide the cap forward until it is flush with the wall.
Wall Mount
6) Snap off the excess strap by pressing the
top strap up and the bottom strap down.
7) Repeat Steps 4-6 for the three remaining
anchors.
8) Place a flat washer on each of the bolts, and
insert the bolts through the mounting holes of the MTU.
9) Thread each bolt into the appropriate
anchor.
10) Tighten each bolt to 5-7 ft. lbs.
26 Series 4000 Maintenance and Operations Manual

Pipe Mount

Hardware Installation
Pipe Mount Kit #109-2015-001M-21
Item Description Quantity
A B
Series 4000 Maintenance and Operations Manual 27
Bracket assembly ( 2 "- 3" Screw-drive tube clamp
5
/16
"-18 bolt, metal washer, nylon washer, & bracket)
2 2
Pipe Mount
Special Tools
In addition to standard hand tools and safety equipment, the Pipe Mounting kit also requires the following:
• 0-20 ft-lb Torque-limiting wrench
• 0-10 in-lb Torque-limiting wrench or screwdriver
1) Thread one of the clamps through both slots
in one of the brackets and around the pipe.
4) There are three mounting holes at the top of
the MTU and three at the bottom.
• If mounting to a Horizontal pipe, use the
top left and top right mounting holes.
• If mounting to a Vertical pipe, use the top
center and bottom center mounting holes.
2) Rotate the bracket to the desired mounting
position and tighten the clamp just enough to maintain bracket position.
3) Thread the remaining clamp through the
remaining bracket and around the pipe.
5) Insert one of the bolts through a metal
washer, the appropriate MTU mounting hole, and a nylon washer before threading it into the bracket.
6) Repeat step 5 with the remaining hardware
to secure MTU to the remaining bracket.
7) Tighten both clamp screws to 7-9 in-lb.
28 Series 4000 Maintenance and Operations Manual
8) Tighten both bracket bolts to 14-16 ft-lb.
Hardware Installation

Wiring

Use the following instructions to connect the MTU to a Honeywell electronic pressure monitor or volume corrector.
Item Description Quantity
A 10' Conduit (Included in mounting kit) 1 B ½" Conduit fitting (Included in mounting kit) 2 C 12' Five conductor cable (Included in mounting kit) 1 D Five pin mating terminal (Included with MTU) 1 E Two pin mating terminal (Included with MTU) 1 F 12’ Two conductor cable (Included in mounting kit) 1
NOTE: This equipment provides non-incendive field wiring outputs for Class I, Division 2,
Group D.
Series 4000 Maintenance and Operations Manual 29
Wiring

Conduit & Fittings

The cable connecting the MTU to the instrument must be routed through the included conduit. Use the following procedure to install the conduit.
1) Remove the nut, sealing ring, and ferrule
from one of the conduit fittings.
2) Slide the nut and sealing ring over the end
of the conduit.
3) Insert the ferrule into the end of the conduit.
4) Thread the fitting body over the ferrule and
secure by tightening the gland nut. Tighten the nut to 28-32 in-lb.
5) Repeat steps 1-4 to secure the remaining
fitting to the other end of the conduit.
8) Secure the fitting to the MTU with the lock
ring. Tighten the ring to 15-19 in-lb.
9) Route the conduit to the instrument.
CAUTION
10) Remove the lock ring from the remaining
Do not bend the conduit smaller than
a 3" radius.
conduit fitting and insert the fitting body into an available opening in the pressure monitor or volume corrector enclosure.
11) Secure the fitting to the instrument
enclosure with the lock ring. Tighten the ring to 15-19 in-lb.
6) Remove a weather seal plug from the
bottom of the MTU enclosure.
7) Remove the lock ring from one of the
conduit fittings and insert the fitting body into the opening in the bottom of the MTU.
30 Series 4000 Maintenance and Operations Manual

MTU Connections

Use the following information when connecting the cables to the MTU.
Hardware Installation
1) Route the cable through the conduit.
2) Use the following information to connect
the cable wires to the MTU mating connector. Secure each wire into the connector by tightening the corresponding set screw.
Comp1
1) Use the five conductor cable to connect the
communication terminals on the MTU with the instrument.
MTU Connector Wire
GND (Ground) Green ALM (Alarm) Yellow GND (Ground) Black TX (MTU Transmission) White RX (MTU Reception) Red
Optional Power
1) Use the two conductor cable to connect the
MTU to an instrument supplied 10-15 VDC power source.
MTU Connector Wire
GND (10-15 VDC ground) Black + (10-15 VDC positive) Red
2) Plug the MTU mating connector into the
COMP1 receptacle.
2) Plug the MTU mating connector into the
EX PWR receptacle.
Series 4000 Maintenance and Operations Manual 31
Wiring

Instrument Connections

Use the information for the appropriate meter type to connect the MTU cable(s) to the instrument. Refer to the Electrical Connection Parameters table for electrical parameters of each connector.
Mini-Max or ERX
Use the following information to connect the MTU cable to a Honeywell Mini-Max volume corrector or ERX pressure monitor.
COMP1
Mini-AT
Use the following information to connect the MTU cable to the TB2 connector on a Honeywell Mini-AT volume corrector.
COMP1
MTU Wire Mini-Max or ERX
GND Green ALM Yellow GND Black TX White RX Red
External Power (Optional)
TB1 A- (Ground) TB1 A+ (Alarm) Serial I/O GND (Ground) Serial I/O RX (Receive) Serial I/O TX (Transmit)
MTU Wire Mini-AT
GND Green A- (Ground) ALM Yellow A+ (Alarm) GND Black Com (Ground) TX White RX (Receive) RX Red TX (Transmit)
Connect the red (positive) and black (ground) wires from the MTU to an appropriate 10-15 VDC auxiliary power source on the instrument. Please refer to specific instrument documentation for detailed information.
Electrical Connection Parameters
COMP1 & COMP2 (J6 & J7) Input Output External Power (J12) Input
Ui = 12 V Uo = 3.5 V Ui = 15 V Ii = 4 mA Io = 60 mA Ii = 45 mA Pi = 50 mW Po = 210 mW Pi = 675 mW Ci = 250 pF Co = 0 pF Li = 0 Lo = 0
32 Series 4000 Maintenance and Operations Manual
Hardware Installation

Commissioning

After installing and connecting the MTU to the instrument, it is necessary to commission the MTU using the Add MTU function of the STAR Programmer software. Please refer to the STAR Programmer Software section on page 7 for more information on connecting the STAR Programmer and adding an MTU.
Series 4000 Maintenance and Operations Manual 33
Commissioning
34 Series 4000 Maintenance and Operations Manual

Maintenance

MAINTENANCE
The Series 4000 MTU is designed to be largely maintenance free. Periodic replacement of the battery, however, will be necessary over the life of the MTU. The Series 4000 MTU is powered by a 3.6V lithium, D cell battery (Aclara part number 042-0049). The NCC reports regular battery voltage readings, and also provides a low battery warning to provide ample time for the utility to replace a battery without loss of data. Use the following procedure to replace the battery in a Series 4000 MTU.
WARNING:
AVERTISSEMENT:
1) Remove any security hardware from the
EXPLOSION HAZARD - BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO
BE NON-HAZARDOUS
RISQUE D'EXPLOSION
L’EMPLACEMENT EST DÉSIGNÉ NON DANGEREUX AVANT DE CHANGER LA BATTERIE.
- AFIN D’ÉVITER OUT RISQU D’EXPLOSION, S’ASURER QUE
MTU door.
2) Open the door of the MTU.
5) Remove the battery from the battery holder.
6) Insert the new battery into the battery
holder. The holder is keyed so the battery can only be installed in one direction.
N
OTE: A backup capacitor will maintain MTU
memory during battery replacement provided power is not removed for longer than 10 minutes. Extended power outages may require recommissioning the MTU.
7) Secure the new battery into the holder by
threading the tapered end of the tie through the open end and pulling until snug against the battery.
8) Use the STAR Programmer to log the
battery replacement.
3) Note the polarity orientation of the battery.
4) Press in on the tab to release the battery tie.
Series 4000 Maintenance and Operations Manual 35
• Connect the STAR Programmer and select
Read MTU to record the battery
replacement in the activity log. Please see Read MTU on page 17 for more information.
• If the MTU was without power for an
extended period of time, use the Replace MTU option on the STAR Programmer Main Menu. Please see Replace MTU on page 20 for more information.
9) Close and secure the MTU door according
to utility standard practices.
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