Badger Meter Galaxy TR3 Installation Manual

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GALAXY® TR3 Gateway

GXY-UM-00760-EN-01 (April 2015)

Installation Manual

GALAXY® TR3 Gateway

Page ii April 2015GXY-UM-00760-EN-01

Installation Manual

CONTENTS

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

License Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Product Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Assembly Size, Weight, Wind Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

REPLACEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Cable and Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

STANDARD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Installation Tools and Materials (Customer-supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

ANTENNAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Attach the Backhaul Antenna (CDMA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

MOUNTING HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Gateway Backplate with Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

MOUNTING THE GATEWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Gateway Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Using V-block Mounting Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Banding Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

POWER SOURCE CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Access to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Use of a NEMA 4 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Recommended Installation Congurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

CDMA or LAN with 120V AC Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

CDMA or LAN with DC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

LAN with Power Over Ethernet (PoE) Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

M12 Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

AC Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Lightning Arrestors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

RJ45 Plug Assembly for LAN Connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

WEATHERPROOFING FOR CONNECTOR/CABLE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

DUAL BACKHAUL CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

PROGRAMMING THE GATEWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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GALAXY® TR3 Gateway

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Overview

OVERVIEW

This manual provides installation instructions for the GALAXY® TR3 gateway receiver.

Proper performance and reliability depends upon installation in accordance with these instructions.

OTE:N Refer to the Gateway Configuration Software manual available at www.badgermeter.com for instructions on

configuring and programming the gateway.

Product Description

The GALAXY TR3 gateway receiver (“gateway”) is an easy-to-install, easy-to-deploy unit that collects metering data from the GALAXY TR3 meter endpoints in the area.

The gateway uses a cellular or LAN network backhaul to forward metering data to the utility where the data can be used to better manage the utility's operation and provide important data for improved customer service and utility operations. The reading data management software (RDMS) manages this data transfer process and includes many tools and standard reports, as well as the ability to create user-defined reports.

License Requirements

This device complies with Part 15, section 247 as an unlicensed transmitter and as a Part 15 unintentional radiator.

This device complies with Part 15 of the FCC rules. Operation is subject to the following two 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 pass the requirements pertaining to RF radiation exposure. However, to avoid public exposure in excess of limits for general population (uncontrolled exposure), a 20-centimeter distance between the transmitter and the body of the user must be maintained during operation.

An FCC license is required to operate a GALAXY 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.

MPORTANTI

Changes or modifications to the equipment that are not expressly approved by Badger Meter could void the user’s authority to operate the equipment. Only properly trained and authorized personnel should install and/or maintain this equipment.

Product Unpacking and Inspection

Upon opening the shipping container, 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.

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Specications

SPECIFICATIONS

Make sure to consider these specifications in your evaluation of an installation location.

MPORTANTI

The GALAXY TR3 gateway is functionally equivalent to the previous GALAXY gateway. However, the physical configuration of the new enclosure is different. This change affects installation considerations, including cabling, size, weight and wind load area.

Installation 1.25…2.5" outside diameter pole mount: Aluminum V-blocks

2.5…24" outside diameter pole mount: BAND-IT® mounting bands

Size Height: 27" (includes antennas)

Width: 36" Depth: 7.3" (includes V-block mounting)

Weight 16.3 lb

Enclosure Sealed, metallized fiberglass reinforced polyester (FRP) enclosure

Color Silver/gray

Operating Temperature –30…60° C (–22…140° F)

Storage Temperature – 40…85° C (– 40…185° F)

Backhaul Options CDMA with LAN

LAN with power LAN with PoE

Power Supply DC voltage, 24V DC (AC adapter provided)

PoE alternative available for LAN

Solar can be used provided it meets DC requirements

Wind Loading Area 1.5 ft

Programming Locally: via programming harness

Assembly Size, Weight, Wind Loading

Gateway Assembly Assembly includes gateway enclosure,

TX/RX antennas, backhaul antenna and V-block mounting

Mounting Hardware

V-block mounting kit 1.6 lb

Banding mounting kit 1.0 lb

Height Width Depth Weight

27" 36" 7.3" 18 lb 1.5 ft

Wind Loading

Area

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GXY-UM-00760-EN-01

Replacement Installation

REPLACEMENT INSTALLATION

If you are replacing an existing GALAXY gateway, review the following information before starting installation. You may be able to re-use the existing cable and power supply.

Cable and Power Supply

Existing Power Supply TR3 Gateway Power Supply

Gray power cable with 12V power supply (Figure 1)

15V DC power supply with 308 connector (Figure 2) or customer-supplied DC power source (see "CDMA or LAN with DC Power

Source" on page 20)

Existing gateway connects via LAN Replace the adapter with an ethernet cable. You cannot re-use the serial-to-LAN

Replace cable and power supply with the new power/communication cable provided with the GALAXY TR3 gateway. See "Chart A: WIRING THE GATEWAY WITH

NEW POWER/COMMUNICATION CABLE" on page 24.

You can re-use the existing cable and power supply but you must wire the M12 connector for the GALAXY TR3 gateway using the wiring diagram provided. See

"Chart B: WIRING THE GATEWAY RE-USING THE GALAXY 3.0/3.3 GATEWAY POWER/ COMMUNICATION CABLE" on page 24.

OTE:N The black cable does not wire directly to the board.

adapter (Figure 3) for the GALAXY TR3 gateway receiver. See "RJ45 Plug Assembly for

LAN Connectivity" on page 28.

Figure 1: Gray power cable and 12V power supply Figure 2: Black cable and 24V power supply

Figure 3: Serial-to-LAN adapter

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Standard Components

STANDARD COMPONENTS

• One gateway receiver with attached mounting backplate and antenna(s).

• V-block clamps or banding and locking equipment for attaching the gateway to a pole.

• 100-foot or 300-foot power/communication cable, M12 connector, AC-to-DC power supply and power cord.

Backhaul Antenna Included for CDMA Configuration

Figure 4: GALAXY TR3 gateway components

FAILURE TO READ AND FOLLOW THE INSTRUCTIONS IN THIS MANUAL CAN LEAD TO MISAPPLICATION OR MISUSE OF THE GALAXY GATEWAY RECEIVER, RESULTING IN PERSONAL INJURY AND DAMAGE TO THE EQUIPMENT.

Installation Tools and Materials (Customer-supplied)

• Phillips #2 screwdriver

• Precision slotted screwdriver with a 2.0 millimeter (0.079 inch) blade size

• Two 9/16 inch or adjustable wrenches for mounting V-block clamps (standard mounting)

• BAND-IT® tool (see "Banding Mounting" on page 16) and instructions, 1/2 inch wrench and a hammer for large diameter pole mounting, if required

• Wrench (for 1-1/16 inch gland nut and 1-1/16 inch dome nut)

• Pliers or strap wrench (for tightening the 15/16 inch OD backhaul antenna and other Type N connectors)

• 7/16 inch socket wrench for all other bolts and nuts

• Cat5e Ethernet cable (outdoor-rated) and RJ45 jack for LAN connection

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ANTENNAS

The gateway ships in a direct mount configuration with the TX/RX antennas attached.

Attach the Backhaul Antenna

1. Remove the plastic cover from the Type N female connector on the backhaul antenna bracket.

2. Remove the backhaul antenna from the carton.

3. Thread the Type N male connector (antenna) onto the Type N female connector on the backhaul antenna bracket.

OTE:N See"Backhaul Antenna Bracket" on page 12 for additional mounting information.

4. Hand tighten until nger tight. Then use pliers or a strap wrench to tighten an additional 1/16 inch turn (maximum). Do not over-tighten or the connector can be damaged.

Antennas

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Mounting Hardware

MOUNTING HARDWARE

Gateway Backplate with Brackets

The backplate of the gateway receiver has a modular design consisting of three brackets—the TX/RX antenna bracket, mounting bracket and backhaul antenna bracket—joined together. When shipped, the three brackets are attached as shown in Figure 5. Together they make up the gateway backplate, which is attached to the gateway enclosure bracket. The brackets can be separated to provide additional mounting options. A description of each bracket starts on the next page.

TX/RX Antenna

Bracket

Mounting Bracket

Backhaul Antenna

Bracket

Figure 5: Gateway backplate

The gateway enclosure is permanently mounted to the enclosure bracket which is used to attach the gateway to the backplate. When shipped, the gateway enclosure bracket is attached securely to the backplate.

Gateway Enclosure

Enclosure Bracket

Figure 6: Gateway receiver enclosure with enclosure bracket

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Mounting Hardware

Mounting Bracket

Machined with multiple holes to accommodate different mounting options, the mounting bracket is the largest part of the gateway backplate. Mounting holes are labeled for V-block, banding and wall mounting options. The bracket also has 1/4 inch and 3/8 inch grounding points (see Figure 7) which can be used if needed.

Used to Mount TX/RX

Antenna Bracket

Used to Mount Backhaul

Antenna Bracket

Grounding Points

Figure 7: Mounting bracket

Mounting Options

The circular hole pattern on the mounting bracket can be used to accommodate mounting the gateway on an angled beam or pole, if necessary.

The gateway can also be mounted on a wall. The mounting bracket has four 0.28 inch holes marked for this option.

OTE:N For a wall mount, customers must supply the mounting hardware suitable for the substructure on which the gateway

is mounted.

For mounting options, all gateway installation considerations must be observed. See "Specifications" on page 6 and

"Installation Tools and Materials (Customer-supplied)" on page 8.

TX/RX Antenna Bracket

The TX/RX antenna bracket is used for mounting the TX/RX antenna. When shipped, the TX/RX antenna bracket is attached to the top of the mounting bracket with three

locknuts using the holes indicated in Figure 8.

Other holes on the bracket can be used to accommodate a variety of mounting options.

Figure 8: TX/RX antenna bracket

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Mounting Hardware

Backhaul Antenna Bracket

The backhaul antenna bracket is used for mounting the backhaul antenna. When shipped, the backhaul antenna bracket is attached to the bottom of the mounting bracket with two locknuts (PN: 67810-001)

using the holes indicated in Figure 9.

Other holes on the bracket can be used to accommodate a variety of mounting options.

A backhaul antenna can be connected to the mounting bracket with either end up. However, the antenna must always be connected at the narrow end, hanging away from the bracket as shown in Figure 10.

Figure 9: Backhaul antenna bracket

Correct Antenna Mount Correct Antenna Mount Incorrect Antenna Mount

Figure 10: Backhaul antenna mounting

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Mounting the Gateway

MOUNTING THE GATEWAY

MPORTANTI

Receiver installation, mounting and disposal shall be in accordance with all local, state and federal regulations. When installing the receiver, customer is responsible for complying with local, state, and federal codes and guidelines, as well as applicable industry standards, such as ANSI/TIA/EIA 222 (structural standards for steel antenna towers and antenna supporting structures) and the National Electrical Code (NEC). Proper grounding is necessary, and in the case of a wooden pole, a dedicated copper ground wire should be used for lightning protection.

Gateway Location

The utility is responsible for properly positioning the gateway. For optimal reception and transmission, locate the gateway and antennas in line-of-sight view of the desired endpoints.

To help maximize the performance of your GALAXY fixed network system, the following installation guidelines and recommendations should be considered when selecting mounting locations for the gateway.

• Avoid installing the gateway next to or between objects such as tall buildings, towers, bridges, highway overpasses or signs that obstruct the line of sight with the endpoints.

• Avoid installing the gateway near RF transmitters or other sources of RF radiation including high-power in band and near-power sources such as pagers, cellular 900 MHz transmitters and communications transmitters. Other potential sources of RF radiation include power line transformers, neon or fluorescent signs, RADAR transmitters and SCADA systems. If the gateway is to be located near other RF radiators, a minimum distance of 100 feet horizontal separation and 10 feet vertical separation must be maintained between the gateway and the source of RF radiation.

• Avoid installing the gateway antennas inside metal enclosures or inside of a building as the antennas cannot communicate if surrounded by metal.

• Mount the gateway as high as possible above average terrain, within the limits of the 300-foot power cable, and maintain a 30 degree view of the horizon.

• Minimum standoff distance of 2 feet from any structure is required.

• Position the gateway no closer than 25 feet from the nearest endpoint.

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Mounting the Gateway

Using V-block Mounting Clamps

The V-block mounting clamps are sized for mounting the gateway on a vertical or horizontal pole with outer diameters ranging from 1-1/4… 2-1/2 inches. For mounting on poles larger than 2-1/2 inches, see "Banding Mounting" on page 16.

1. Open the bag of mounting equipment.

2. Place two bolts (3/8-16 x 5 inches) through the holes in the top of the gateway mounting backplate (Figure 11). Use the backplate circular pattern holes for horizontal installation.

3. Place a clamp onto the bolts, as shown below.

4. Place a lock washer and nut onto each bolt, as shown below.

OTE:N The lock washer and nut nearest the enclosure mounting bracket can be omitted when mounting on smaller

diameter poles to provide additional clamping distance.

Figure 11: Mounting clamp at top of the backplate

5. Tighten the two nuts with a 9/16 inch or adjustable wrench so that each lock washer is fully compressed and at.

6. Repeat steps 2 through 5, attaching a clamp to the bottom of the gateway mounting backplate. Position the gateway on the pole and place a clamp on the top bolts.

Lock Washers

Bolts

Nuts

Clamps

Page 14 April 2015GXY-UM-00760-EN-01

Figure 12: Clamps with hardware

Mounting the Gateway

7. Place a lock washer and nut on each bolt and tighten the nuts 100…150 inch-pounds to ensure the gateway is

suciently secured to the pole.

8. Repeat steps 7 and 8 for attaching the V-block clamp mounting hardware to the bottom bolts of the

mounting backplate.

Side View

V-block mounting is complete.

Back View

Side View

Figure 13: Completed gateway mounting

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Mounting the Gateway

Banding Mounting

Banding mounting equipment is sized to mount the gateway on a 2-1/2…24 inch outer diameter pole.

OTE:N Installation of banding mounting requires the use of the BAND-IT tool (PN: 66042-006) or equivalent BAND-IT tool as

recommended by BAND-IT.

MPORTANTI

When using the banding mounting kit for the gateway, use BAND-IT Idex installation practices. Refer to

www.band-it-idex.com/en/Literature/Tool_Instructions/P05886.pdf for more information. This is especially applicable when

mounting on a non-tapered vertical pole, as the banding could loosen over time resulting in the unit sliding down the pole.

Figure 14: Banding and locking equipment Figure 15: BAND-IT tool

1. To mount the gateway on a pole, gather the banding and locking equipment.

2. Locate the BAND-IT tool and supplied installation instructions.

3. Follow the installation instructions enclosed with the BAND-IT tool for attaching the gateway receiver to a pole.

4. Using a 1/2 inch wrench, apply the recommended torque for the 5/16-24 screw that attaches the gateway bracket to the BAND-IT banding. The recommended torque is 144…168 inch-pounds (12…14 foot-pounds).

Figure 16: Gateway shown with BAND-IT mounting hardware

Banding mounting is complete.

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Power Source Congurations

POWER SOURCE CONFIGURATIONS

Access to Power

• The gateway receiver requires access to power. The gateway can use a 120V AC grounded outlet for use with the

AC-to-DC power supply and power cord (PN: 66528-003), or a DC power source for use with the DC power source cable with 308 in-line connector (PN: 66233-020). For a gateway with a LAN PoE configuration, a Power over Ethernet

connection is required. Diagrams of each power source configuration start on page 18.

• Outlet and enclosure (if required) should be mounted for easy accessibility by authorized utility personnel at the

installation site.

• Consult the appropriate electrical, building and industry codes, regulations and standards for accepted installation

practices for use of the AC-to-DC power supply and outlet in environmentally controlled indoor locations.

Use of a NEMA 4 Enclosure

AC-to-DC power supply used outdoors or in a non-environmentally controlled indoor location requires a customer-supplied NEMA 4 enclosure, or equivalent, installed in accordance with appropriate electrical codes, building codes, industry codes, regulations and standards.

Recommended Installation Congurations

These are the standard recommended installation configurations with various combinations of backhaul and power source:

• CDMA with 120V AC power source

• LAN with 120V AC power source

• CDMA with DC power source

• LAN with DC power source

• LAN with PoE power source

Diagrams of the above configurations are shown on the pages that follow. Consult the appropriate diagram for your installation configuration.

Page 17 April 2015 GXY-UM-00760-EN-01

Power Source Congurations

CDMA or LAN with 120V AC Power Source

Configurations for a 120V AC grounded outlet with CDMA and LAN are shown here.

CDMA Connection with 120V AC Power Source

ORION SE Power Cable with

308 In-line Connector

(supplied)

AC to DC Power Supply with

308 In-line Connector End and

Power Supply Cable with

308 In-line Connector

Power Cord (supplied)

120VAC

Grounded Outlet

(customer

supplied)

Figure 17: CDMA connection with AC power source (*Shown with NEMA 4 enclosure)

*An enclosure may be recommended but is not included. If NEMA 4 enclosure or equivalent is required, as in an outdoor installation, the minimum enclosure size is 12 inch x 10 inch x 6 inch (H x W x D).

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Power Source Congurations

LAN with 120V AC Power Source

OTE:N Consult the manufacturer's installation and usage recommendations as well as appropriate codes, regulations and

standards for the LAN RJ45 Ethernet connection.

Outdoor-rated

CAT5e Ethernet

Cable (customer

supplied)

To Utility

Network

ORION SE Power Cable with

308 In-line Connector

(supplied)

Power Supply Cable with

308 In-line Connector

LAN RJ45 Ethernet

Connection

(customer supplied)

AC to DC Power Supply with 308

In-line Connector End and Power Cord

(supplied)

120VAC

Grounded Outlet

(customer

supplied)

Figure 18: LAN connection with AC power source (*Shown with NEMA 4 enclosure)

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Power Source Congurations

CDMA or LAN with DC Power Source

The gateway receiver can be ordered with a 10-foot DC power source cable (PN: 66233-020) for direct connection with a customer-supplied DC power source. The gateway requires about 6W average power and 12W peak power. When connecting an AC-to-DC power supply, use a power supply rated at 1A (minimum) at 24V DC.

OTE:N Consult the appropriate electrical, building and industry codes, regulations and standards for accepted installation

practices when attaching the cable to a DC power source.

Figure 19: 10' DC power cable

Absolute Requirements

The gateway can be powered by a DC voltage source between 12…30V. Cable length must be reduced to 100 feet, or less, if less than a 24V source is being used. For reference, when connecting directly to batteries, as in a solar assembly (not supplied), the average electrical load is 12V DC at 0.5A continuous. Cables, fuses and/or circuit breakers MUST be capable of handling at least 1A peak currents.

External DC Power Source Connections

Wire Color for PN: 66233-020 External DC Power Source

Drain (no insulation) Negative (–)

Black Negative (–)

Brown Negative (–)

Red Positive (+)

Blue Positive (+)

Page 20 April 2015GXY-UM-00760-EN-01

CDMA Connection with DC Power Source

DC Power Source

(customer supplied)

10-foot DC Power Source Cable with 308 In-line Connector End

(supplied)

ORION SE Power Cable with

308 In-line Connector

(supplied)

Power Source Congurations

Figure 20: CDMA connection with DC power source (*Shown with NEMA 4 enclosure)

LAN Connection with DC Power Source

OTE:N Consult the manufacturer's installation and usage recommendations as well as appropriate codes, regulations and

standards for the LAN RJ45 Ethernet connection.

ORION SE Power Cable with

308 In-line Connector End

10-foot DC Power Source Cable with 308 In-line Connector End (supplied)

(supplied)

DC Power Source (customer supplied)

CAT5e Outdoor-rated

Ethernet Cable

(customer supplied)

To Utility

Network

LAN RJ45 Ethernet

Connection

(customer supplied)

Figure 21: LAN connection with DC power source (*Shown with NEMA 4 enclosure)

Page 21 April 2015 GXY-UM-00760-EN-01

Power Source Congurations

LAN with Power Over Ethernet (PoE) Power Source

OTE:N Consult the manufacturer's installation and usage recommendations as well as appropriate codes, regulations and/or

standards for the LAN RJ45 Ethernet connection.

CAT5e Outdoor-rated

Ethernet Cable

(customer supplied)

PoE LAN RJ45

Ethernet

Connection

(customer

supplied)

To Utility Network

Figure 22: LAN with PoE power source connection (*Shown with NEMA 4 enclosure)

Page 22 April 2015GXY-UM-00760-EN-01

Electrical Connections

ELECTRICAL CONNECTIONS

M12 Connector Assembly

The M12 connector assembly is required for all power source configurations except LAN with PoE.

OTE:N Use only approved Badger Meter power cable, 100-foot (PN: 66233-015) or 300-foot (PN: 66233-017), for

this assembly.

Tools and Materials

Included with gateway:

• M12 plug, 8-conductor connector (PN: 66525-002)

• Badger Meter power cable, 100-foot or 300-foot, with 308 in-line connector end

• 308 in-line connector anti-tamper collar

Customer-supplied tools:

• Coax stripper

• Wire stripper for 22 AWG wires

• Precision slotted screwdriver with blade size of 2.0 millimeter (0.079 inch)

M12 Plug Connector Parts

Female Insert Coupling Sleeve Sleeve

w/O-ring

Figure 23: M12 plug connector parts

Cable

Seal

Clamping

Cage

Pressure Nut

Assemble and Connect M12 Plug to Gateway

1. Slide the pressure nut, clamping cage, cable seal, sleeve with O-ring and the coupling sleeve onto the power cable in

order as shown in Figure 23.

2. Strip the power cable outer jacket to a maximum length of 1.1 inches.

3. Peel back the foil shield ush with the outer jacket.

4. Strip the ends of the colored wires to a length of 1/8 inch. Twist the exposed conductors on each wire.

Twist Exposed Conductors

Foil Shield Flush with Outer Jacket

1.1"

Figure 24: Stripped cable wires

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Electrical Connections

5. Shorten the drain/bare wire (no insulation) to 11/16 inch.

6. On the female insert, loosen each of the screws (about 2…3 turns) and attach the wires to the insert using the appropriate wiring chart (A or B) below.

Tighten each screw after each wire is connected.

BE CAREFUL NOT TO BACK THE SCREWS OUT TOO FAR. THE SCREWS ARE SMALL AND CAN EASILY BE LOST IF THEY ARE DROPPED.

OTE:N If you need help determining which wiring chart to use, see "Replacement Installation" on page 7.

Chart A: WIRING THE GATEWAY WITH NEW POWER/COMMUNICATION CABLE

Function Wire Female insert connector

V DC+ Red 1

Brown

Slot

Red

V DC– Brown 2

V DC– Black 3

RS232 White* 4

Black

RS232 Green* 5

Not used Not used 6

V DC+ Blue 7

V DC– Drain** 8 (Center)

Female Insert Diagram - Top View

White

Green

Female Insert Photo - Top View

Used

Chart B: WIRING THE GATEWAY RE-USING THE GALAXY 3.0/3.3 GATEWAY POWER/COMMUNICATION CABLE

Function Wire Female insert connector

V DC+ Red 1

Not used Not used 2

V DC– Black 3

RS232 White* 4

RS232 Green* 5

Not used Not used 6

Not used Not used 7

V DC– Drain** 8 (Center)

Not

Used

Black

White

Slot

Green

Red

Used

Drain

Blue

Not

Drain

Not

Used

Not

* Used with the serial programming harness (PN: 66529-002) ** Used with shielded cable only

OTE:N For information about DC power source, see"Absolute Requirements" on page 20.

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Female Insert Diagram - Top View

Female Insert Photo - Top View

Electrical Connections

7. Align the tab slot of the female insert (with attached wires) with the notch in the coupling sleeve. Connect the insert

with the coupling sleeve and screw clockwise to tighten.

Female Insert

Tab Slot

Figure 25: Slot alignment

Coupling Sleeve Insert

Notch

8. Finish assembly by sliding the pressure nut with clamping cage and cable seal onto the coupling sleeve. The

clamping cage and cable seal t inside the pressure nut.

9. Screw the pressure nut counterclockwise onto the coupling sleeve and tighten it so that the cable seal makes rm

contact with the cable.

10. Remove the cap from the M12 receptacle on the bottom of the gateway. Save the cap so it can be replaced if the

power cable is removed later.

Figure 26: Gateway receiver

M12 Receptacle with Cap Removed

RJ45 Receptacle

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Electrical Connections

11. Connect the M12 plug connector assembly to the M12 receptacle on the gateway by aligning the plug notch with the receptacle notch. Turn the locking ring clockwise until the connection is nger tight.

M 12 Plug

Notch

M12 Receptacle

Notch

13. Connect the 308 connector on the other end of the power cable to the 308 connector of the AC-to-DC power supply and snap the anti-tamper collar over the connection.

14. Connect the power cord to the power supply and then plug the three-prong male end of the power cord into a 120V AC power source. The LED indicator above the M12 connection turns on with a steady green light, indicating the gateway power is on (Figure 27).

OTE:N If there is no light, the gateway is not receiving power.

Steady Green Light Indicates Gateway Power is On

The M12 connection is complete.

Figure 27: Powered gateway

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Electrical Connections

AC Power

Badger Meter provides an Emerson AC-to-DC power supply with cord (PN: 66528-003) that plugs into a standard three-prong 120V AC outlet. If you are powering the gateway directly via DC power, see"CDMA or LAN with DC Power Source"

on page 20.

Figure 28: 120V AC power supply with power cord

OTE:N If you replace a gateway, make sure to replace the power supply cord with the Emerson power supply cord at the

same time.

Lightning Arrestors

Lightning arrestors are recommended for all standard and remote antenna installations. If lightning arrestors are used, they should be placed directly between the gateway enclosure and the antenna cable connector and grounded per code. One lightning arrestor is shown in Figure 29. Arrows indicate where other lightning arrestors should be attached.

Lightning arrestors for both the TX/RX antennas as well as the backhaul antenna (if applicable), should meet the following specifications:

• Operating bandwidth

- TX/RX antennas: 450 MHz…1 GHz

- Backhaul antenna: 824 MHz…1990 MHz

• Impedance: 50 Ω

• Power handling (average): 2W, minimum

• Environmental/weather rating suitable for the location

Figure 29: One lightning arrestor attached (ground is not pictured).

Arrows indicate where additional lightning arrestors should

be attached.

• N male connector on the protected side; N female connector on the surge side

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Electrical Connections

RJ45 Plug Assembly for LAN Connectivity

Use this procedure to connect an Ethernet cable to the gateway for a LAN backhaul or any PoE connection.

Required Supplies:

• RJ45 Plug Assembly (PN: 66527-001) as shown in Figure 30

• Cat5e Ethernet cable (limited to 300 feet of outdoor-rated cable) and available LAN connection (customer-supplied)

• Wrenches – 1-1/16 inch (customer-supplied)

Cable Gland

Nut

Metal Housing Insulator Halves Cable Gland

Figure 30: RJ45 plug components

1. Separate the RJ45 plug pieces:

• Unscrew the cable gland from the metal housing and put the metal housing aside for use in step 4.

• For ease of installation, remove the gray seal from inside the cable gland body as shown in Figure 31.

2. In the following order, thread the dome nut, gray seal and cable gland body onto the Ethernet cable as shown in Figure 32.

Dome Nut

Figure 31: Remove gray seal

3. Reassemble the parts on the Ethernet cable by reinserting the gray seal into the cable gland body and loosely screwing the dome nut onto the cable gland body.

OTE:N Do not screw together tightly at

this time.

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Figure 32: Thread nut, seal and cable gland

4. Attach the metal housing to the

RJ45 receptacle on the gateway:

• Remove the RJ45 receptacle bayonet lock cap from the gateway by turning the cap 1/4 turn counter clockwise.

OTE:N The RJ45 receptacle cap

should be saved so it can be replaced if the Ethernet cable is removed later.

Electrical Connections

RJ45 Receptacle Bayonet

Lock Cap

• Place the metal housing on the RJ45 receptacle and turn it until you feel the metal housing align with the keys on the RJ45 receptacle (Figure 34).

Once aligned, tighten the outer sleeve on the metal housing 1/4 turn clockwise.

OTE:N The metal housing fits on

the RJ45 receptacle correctly when it is aligned with the keys on the RJ45 receptacle.

5. Attach the half insulators to the RJ45 modular plug on the Ethernet cable connector:

• Hold down the plug latch and slide one of the half insulators over the latch. Make sure the half insulator prong is aligned next to the plug latch as shown in Figure 36.

• Slide the other half insulator over the other side of the latch while holding the half insulator you just attached, again making sure the prong is aligned next to the plug latch.

Figure 34: Remove bayonet lock cap

Figure 35: Plug latch

Figure 33: Bayonet lock cap

Figure 36: Half insulator over latch

• Squeeze both insulators together to connect. You will hear a “click” when the connection is made. The plug with both half insulators is shown in Figure 37.

Figure 37: Half insulators connected

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Electrical Connections

6. Insert the Ethernet cable connector into the RJ45 receptacle. Push the connector in rmly.

The plug latch of the connector ts into the recessed key section of the RJ45 receptacle. A close-up view from the front is shown in Figure 38.

An audible click conrms a complete connection.

OTE:N Once assembled, RJ45 plugs

cannot be disassembled from the metal housing without a special tool (PN: 67163-001).

Figure 38: RJ45 receptacle close up

7. Screw the cable gland onto the metal housing on the RJ45 receptacle and tighten the cable gland nut. See Figure 39 and Figure 40. Recommended: Use a torque wrench to tighten to 30…45 inch-pounds.

8. Tighten the dome nut on the cable gland (Figure 41). Recommended: Use a torque wrench to tighten to 20 inch-pounds.

OTE:N The gray seal inside the dome nut must be in firm contact with the Ethernet cable. As the dome nut is

tightened, the seal should fill the open end of the dome nut without popping out the front and should be in firm contact with the outer jacket of the Ethernet cable. See Figure 41 and Figure 42.

Figure 39: Screw cable gland onto metal housing

Figure 41: Gray seal before dome nut is tightened

Assembly is complete. For additional information, refer to http://www.rjfield.com/Ethernet_connectors_rjf_en.htm.

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Figure 40: Tighten the cable gland nut

Figure 42: Gray seal after dome nut is tightened

Weatherproong for Connector/Cable Connections

WEATHERPROOFING FOR CONNECTOR/CABLE CONNECTIONS

Weatherproofing material should be provided by the installation contractor. Badger Meter recommends weatherproofing for all connections according to cable and connector manufacturer recommendations. Weatherproofing provides additional moisture protection and will prevent the connections from loosening due to vibrations.

MPORTANTI

The backhaul antenna is designed with vent holes. Any weatherproofing applied to the Type N connectors must not obstruct this venting or the antenna can be damaged.

On the backhaul antenna, vent holes are located at each end (Figure 43). At the bottom end with the Type N male connector, vent holes are on the outside, on the metal section. At the top, vent holes are incorporated into the cap.

Vent Hole

Figure 43: Vent holes at bottom and top of backhaul antenna

DUAL BACKHAUL CONFIGURATION

GALAXY TR3 network gateway receivers are configured to allow a dual backhaul connection so you can switch from CDMA to an alternative LAN backhaul, if necessary, using the RJ45 plug assembly included with the receiver.

The CDMA connection can remain in place when the LAN connection is set up. See"LAN with 120V AC Power Source" on page

19 for the LAN installation diagram.

OTE:N The gateway will need to be reprogrammed for a LAN connection. Refer to the Gateway Configuration Software

manual, available at www.badgermeter.com, for programming instructions.

PROGRAMMING THE GATEWAY

The GALAXY gateway is programmed using a 5- or 7-pin programming harness, depending on the gateway power cable. Check the connector end of the gateway power cable. The power cable with a 7-pin connector requires the 7-pin programming harness, PN: 66529-002. The power cable with a 5-pin connector requires the 5-pin programming harness, PN: 66529-001. See examples of the connectors below in Figure 44.

7-pin power cable connector

PN: 66233-015, -017

7- pin programming harness

PN: 66529-002

Figure 44: Power cable and programming harness connectors

5-pin power cable connector

PN: 66233-010, -013

5- pin programming harness

PN: 66529-001

The programming kit is required for configuring the settings of the GALAXY TR3 gateway. The kit (PN: 67577-002) includes the configuration software, the ORION® and GALAXY Configuration Software manual, USB to serial adapter and serial programming harness. The ORION and GALAXY Configuration Software manual is also available on the website at www.badgermeter.com.

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GALAXY® TR3 Gateway

Making Water Visible®

GALAXY, 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 extent an outstanding contractual obligation exists. © 2015 Badger Meter, Inc. All rights reserved.

www.badgermeter.com

Badger Meter Galaxy TR3 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual