RM4000 Series Installation and Configuration Guide Series Installation and Configuration Guide d e t r a t S g n i t t e 2G NOTE: For information about how to download files from the

RM4000 Series

Installation and Configuration Guide

Information in this document is subject to change without notice.

© 1999-2013 American Innovations, Ltd. All rights reserved.American Innovations | www.aiworldwide.com | 12211 Technology Blvd | Austin, TX 78727

Reproduction in any manner whatsoever without the written permission of American Innovations is strictly forbidden.

Trademarks used in this text: the American Innovations logo and icon are trademarks of American Innovations, Ltd. The Bullhorn logo and icon are registered trademarks of American Innovations, Ltd. Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries.

Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and names or their products. American Innovations, Ltd. disclaims any proprietary interest in trademarks and trade names other than its own.

June 23, 2014 Part No. 122173-000, Rev. 3

http://www.aiworldwide.com

Contents

Change Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

CHAPTER 1Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ESD Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Lithium Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Safety and Equipment Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Bullhorn System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4RM4000 Series Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Required Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Hardware / Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Universal Configuration Toolkit Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Microsoft .NET Framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9USB Device Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9BATtools Suite Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Installing the UCT and Support Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12USB Driver Does Not Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Bullhorn Information Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Contacting Technical Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

CHAPTER 2RM4010 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

RM4010 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Preparing for the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Installing Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Mounting the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Mounting the Enclosure on a Metal Pole or Pipe . . . . . . . . . . . . . . . . . . . . . . . . 21Installing the GPS Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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RM4000 Installation and Configuration Guide

Installing the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Installing the Surge Arrester (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Connecting Unit Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Installing the Satellite Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Find Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Install Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Verify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installing the Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Connecting Input Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28


RM4011 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Preparing for the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Installing Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Placement / Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Mounting the Enclosure - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Installing the GPS Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Installing the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Installing the Surge Arrester (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Installing Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Installing the Satellite Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Find Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Install Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Verify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Installing the Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Connecting Input Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44


RM4013 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Preparing for the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Installing Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Mounting the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Mounting the Enclosure on a Metal Pole or Pipe . . . . . . . . . . . . . . . . . . . . . . . . 52Alternate Mounting Method on a Flat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Installing the Antenna/Surge Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Installing the Solar Panel Battery Charger (1.65 Watt) . . . . . . . . . . . . . . . . . . . . . . . . 56Establish Communications with the ORBCOMM Satellite . . . . . . . . . . . . . . . . . . . . . 58Connecting Input Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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RM4020 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Preparing for the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Installing Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Mounting the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Mounting the Enclosure on a Metal Pole or Pipe . . . . . . . . . . . . . . . . . . . . . . . . 67Installing the Antenna/Surge Arrester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Installing the Surge Arrester (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Connecting Unit Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Installing the Solar Panel Battery Charger (1.65 Watt) . . . . . . . . . . . . . . . . . . . . . . . . 72Establish Communications with the ORBCOMM Satellite . . . . . . . . . . . . . . . . . . . . . 74Connecting Input Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

CHAPTER 6RM4000 Series Configuration . . . . . . . . . . . . . . . . . . . . . . . 77

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Configuration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Disable Synchronization Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Connect the Unit and Start UCT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Load Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Choose Folder for Templates and Log Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Select SkyWave Satellite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Select International Gateway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Set Up Controller Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Set Up Transmission Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Set Up Interrupter Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Set Up Power Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Set Up Battery Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Set Up Input Channels and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Set Up Input Channel for Analog Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Set Up Input Channel for Digital Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Set Up Channel 5 for Accumulator Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Verify Interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Transmit a Test Packet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Save Settings in the Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Save Settings in a Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Exit UCT and Close the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

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APPENDIX ATechnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

APPENDIX BBattery and Fuse Replacement . . . . . . . . . . . . . . . . . . . . . 101

Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Replacing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

APPENDIX COptional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

AC Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Mounting on a Flat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

APPENDIX DMercury Relay Customer Advisory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Mercury Relay Customer Advisory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

APPENDIX ERegulatory Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

FCC Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Export Control Classification Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

APPENDIX FGlossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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Change Notes

The following list identifies new or updated information included in the current release of this manual:

• Chapter 1: Safety information. Refer to Chapter 1, Getting Started on page 1.

• Chapter 2: Added new installation requirements for unit and power supply. Refer to Chapter 2, RM4010 Installation on page 15.

• Chapter 3: Added new installation requirements for unit and power supply. Refer to Chapter 3, RM4011 Installation on page 31.

• Appendix A: Added new technical information and equipment rates. Refer to Appendix A, Technical Specifications on page 99.

• Appendix B: Added instructions on how to change the battery and fuse in the RM4010. Refer to Appendix B, Battery and Fuse Replacement on page 101

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RM4000 Series Installation and Configuration Guide

x

1

Getting Started

This guide explains how to install and configure Bullhorn® RM4000 Series units for service using the Universal Configuration Toolkit (UCT) software. The information applies to the RM4010, RM4011, RM4013, and RM4020 units that use SkyWave-Inmarsat and ORBCOMM satellite network services for communication with the Bullhorn Asset Tracker (BAT) website.

This guide provides the following information:

• Chapter 1 - Getting Started

• Chapter 2 - RM4010 Installation




• Chapter 6 - RM4000 Series Configuration

• Appendices A - F

NOTE: The configuration kit includes a copy of this document in Adobe® PDF format. You can also download a copy from the Bullhorn Asset Tracker website. Use Adobe® Reader® version 5 or higher to view the PDF. If needed, visit the Adobe website at http://www.adobe.com to download a free copy of the software.

1

http://www.adobe.com

http://www.adobe.com


NOTE: For information about how to download files from the BAT website, see BATtools Suite Installer on page 10.

ESD Precautions

WARNING: To prevent electrostatic discharge (ESD) damage when handling electronic equipment, always wear an antistatic wrist strap attached to an unpainted, grounded metal object. Ensure the wrist strap has maximum contact with bare skin.

If an antistatic wrist strap is unavailable, discharge static electricity from yourself and your clothing by touching a grounded metal object before handling electronic equipment.

Lithium Battery Precautions

WARNING: To protect against personal injury or damage to the lithium battery, observe the following precautions prior to using the battery.

Lithium batteries may get hot, explode, or ignite and cause serious injury if exposed to abuse conditions. Make sure to observe the following safety warnings:

• Do not install the battery backwards so the polarity is reversed.

• Do not connect the positive terminal and negative terminal of the battery to each other with any metal object (such as wire).

• Do not carry or store the battery together with bracelets, necklaces, rings, or other metal objects.

• Do not pierce the battery with nails, strike the battery with a hammer, step on the battery, or otherwise subject it to strong impacts or shocks.

• Do not place the battery in fire or heat the battery.

• Do not solder directly onto the battery.

• Do not expose the battery to water or salt water, or allow the battery to get wet.

2 Getting Started


• Do not disassemble or modify the battery. The battery contains safety and protection devices, which, if damaged, may cause the battery to generate heat, explode, or ignite.

• Do not place the battery in or near fire, on stoves, or other high temperature locations.

• Do not place the battery in direct sunlight. Doing so may cause the battery to generate heat, explode, or ignite. Using the battery in this manner may also result in a loss of performance and a shortened life expectancy.

Safety and Equipment Symbols

WARNING: If any unit in the RM4000 Series is used in a manner not specified by AI, the protection provided by the equipment may be impaired.

The information in the following table provides a description of the safety and equipment symbols present on the outside and inside of the enclosure. Safety symbols alert you of safety hazards or conditions that have the potential to cause personal injury, death, or equipment damage. Equipment symbols may indicate a functional state (such as on and off) and connections (such as a Earth ground terminal).

Getting Started 3


Bullhorn System OverviewBullhorn is a wireless telemetry system that provides scheduled and by-exception inbound reporting for field equipment typically located in remote areas. Data and alarm packets transmit from remote field locations to your account on the secure, Bullhorn Asset Tracker (BAT) website (http://www.bullhornsys.com) using digital cellular or satellite communication networks. You can quickly determine the status of field equipment anytime using information that posts to your website account.

Bullhorn provides remote monitoring with full coverage using GSM cellular, GEOS satellite (SkyWave-Inmarsat), or LEOS satellite (ORBCOMM) communication networks.

Table 1-1. Safety and Equipment Symbols

Symbol Description

Caution: Failure to observe this warning may result in personal injury, death, or equipment damage. A potential risk exists if the installation instructions are not followed.

Warning: Risk of electrical shock. Failure to observe this warning may result in personal injury, death, or equipment damage. A potential risk exists if the installation instructions are not followed.

Earth (ground) terminal: Indicates a protective earth ground connection is required.

On (Supply): Indicates power is on when the toggle switch is in the “ON” position.

Off (Supply): Indicates power is off when the toggle switch is in the “OFF” position.

DC power: Indicates that the input requires DC power.

Both direct and alternating current.

Positive: Indicates a positive input.

Negative: Indicates a negative input.

4 Getting Started

http://www.bullhornsys.com


RM4000 Series OverviewRM4000 Series units, including the RM4010, RM4011, RM4013, and RM4020, monitor oil and gas assets in cathodic protection (CP) applications. The RM4010 measures the output of rectifier current across shunt resistors.

RM4000 Series units use satellite networks for communication with the Bullhorn Asset Tracker website. RM4010, RM4011, and RM4013 (with the capability of two-way communication) use the SkyWave-Inmarsat satellite network; RM4020 uses the ORBCOMM satellite network. RM4000 Series units transmit channel measurements and alarms to your website account.

NOTE: To view a satellite coverage map, log on to the Bullhorn Asset Tracker (BAT) website at http://www.bullhornsys.com, click Help, and then Coverage Maps in the navigation menu.

RM4000 Series units provide built-in surge protection, rectifier interface, and test point filtering functionality. Additionally the RM4010 and RM4011 also support GPS synchronized current interruption, either factory-installed or field-upgraded. RM4010, RM4011, RM4013, and RM4020 support six (6) configurable inputs with the following specifications:

• Input Channels 1, 3, and 4 are isolated inputs that support analog ±50 mV, ±5 V DC, 4 to 20 mA with external resistor, and active digital input devices.

• Input Channel 2 is an isolated input that supports analog ±5 V DC, ±100 V DC, 4 to 20 mA with external resistor, and active digital input devices.

• Input Channels 5 and 6 are non-isolated inputs that support 0 - 15 V DC digital dry contact closure and active digital input devices. Channel 5 can also be used as a pulse count accumulator, and Channel 6 can also be used as an accumulator reset.

Installation RequirementsBefore you install any RM4000 Series unit, use the following information as a checklist to ensure a successful installation:

Getting Started 5

http://www.bullhornsys.com


Power Disconnect and Branch Circuit Protection:A customer-supplied, power disconnect device is required for the unit installation. The power disconnect device (such as a switch, main circuit breaker, or other type of power disconnect) should provide an easy and accessible means for removing the main input supply power source from the unit. Multiple-pole circuit breakers shall interrupt all neutral and ungrounded connectors of mains supply simultaneously. The power disconnect device must be clearly marked to identify it as the disconnect device for the unit. The power disconnect or separate overcurrent protection device should also provide overcurrent protection in the form of a 20 amp fuse or circuit breaker suitable for branch circuit protection per local codes and requirements.

Backup Battery:The RM4010 should only be used with a 12 V DC, 3.4 AH capacity, re-chargeable sealed lead acid battery (American Innovations part number 370042-000; manufacturer’s part number PS-1230). The RM4011 should only be used with a 12 V DC, 2.0 AH capacity, re-chargeable sealed lead acid battery (American Innovations part number 370149-000; manufacturer’s part number PS-1221S). If you need to replace the battery, please contact Technical Support for information about purchasing a replacement battery

NOTE:Refer to Appendix B, Battery and Fuse Replacement on page 101 for instructions on changing the backup battery.

Wiring Requirements: For optimum protection from transient voltages (typically, Channels 1 and 2), all analog inputs must be in their own multi-conductor jacket cable (such as cable AI part number 211061-000 - Belden 5308UE, or its equivalent). All cables must have intact outer jackets, except for end cuts. Do not remove cable jackets as they protect the unit input cable from transient voltages. Cable insulation should be suited for voltage range of inputs. Cables should be rated at a minimum of 600 V and 105˚ C.

Input Channel Voltage Levels: All input channels are marked with acceptable input voltage ranges. Ensure that devices connected to the RM4000 units fall within the voltages ranges listed next to the channel input connections.

Earth (ground) terminal: Indicates a protective earth ground connection is required. The RM4000 series units require grounding.

• Antenna Installation: The dual GSM/GPS antenna should be placed outside the rectifier.

6 Getting Started


• Mounting the Enclosure: Choose an area that provides enough room to easily access the unit or to perform routine maintenance after completing the installation. Use the information in the specific unit installation chapter when deciding where to install the unit.

WARNING: Only accessories that meet American Innovation’s specifications may be used with the RM4000 Series units.

Required Tools and Equipment

WARNING: Equipment intended to be mounted on a wall or ceiling shall withstand a force of four times (4x) the weight of the equipment.

The following tools and equipment are required for installing and configuring the unit for service:

• Antistatic wrist strap

• Small slotted screwdriver

• Small Phillips head screwdriver

• Wire stripper

• Wire cutter

• Voltmeter

• Adjustable wrench (for solar panel battery charger installation)

• Socket or open end wrench set

• Compass

• Waterproof sealing tape

• Silicon adhesive

• Mounting hardware (appropriate type for mounting surface; supplied by customer)

• Appropriate tools for preparing the mounting surface for installation (such as a hand drill and metal, masonry, or wood drilling bit)

Getting Started 7


• Installation drawing (provided in installation kit)

• Configuration cable (provided in installation kit; standard mini USB cable typically used with most digital cameras)

Hardware / SoftwareIBM-compatible computer with the following hardware and software specifications:

• Pentium® processor or equivalent

• 256 MB RAM (minimum)

• 70 MB free hard drive space

• Spare RS232 serial port or USB port

• Microsoft® Windows XP operating system with Service Pack 2 or 3; Vista® Home Premium, Business, or Ultimate with Service Pack 1 or higher; or Windows 7® Home Premium, Professional, or Ultimate

• Universal Configuration Toolkit Software (provided)

• Windows .NET Framework version 4.0 or higher (provided)

• USB device driver (provided)

• Windows® Internet Explorer® version 8.0 or higher

• Adobe® Reader® version 6.0 or higher

Universal Configuration Toolkit SoftwareUniversal Configuration Toolkit (UCT) is a software program you use to set and read the adjustable parameters of the unit. After installing the unit, you then configure it for service using the UCT software.

The UCT software also provides diagnostic tools for checking input channel measurements, RSSI and Signal Strength level, and transmitting a test packet to confirm communications with the BAT website.

Using the UCT software requires that your computer be installed with Microsoft® .NET Framework version 2.0 or higher. If you plan to install a unit that includes a USB configuration port (RM4010, RM4011, RM4013, and RM4020), your computer must also be installed with the appropriate USB device driver.

8 Getting Started


NOTE: You must log on to your computer as an administrator or your computer user name must be a member of the Administrators group in order to install the USB device driver. If needed, contact your network administrator or IT department to determine if your user name is setup with administrator rights or privileges.

Microsoft .NET FrameworkTo run the UCT software, your computer must first be installed with Microsoft® .NET Framework version 1.1 or higher. Microsoft .NET Framework is a set of software components that enable your computer to run any software program that has been developed using Microsoft .NET technology. The installation program for the UCT software and Microsoft .NET Framework are both included in the installation kit (BATtools). When you install .NET Framework or the UCT software on your computer, a setup program guides you through the installation process as files copy to your computer’s hard drive. The UCT software installation also creates a program icon on your computer desktop. You can also start the UCT software using the Windows Start menu (Start > Programs > Configuration Toolkit).

For more information about Microsoft .NET Framework, visit the Microsoft website at the following web address:

http://www.microsoft.com

USB Device DriverThe USB device driver is software that allows your computer to communicate with the Bullhorn unit via the USB configuration cable when configuring the unit for service.

Installing the USB device driver is a one-time process and does not need to be repeated if you have already installed the driver on your computer. Once it is installed on your computer, it will work for any Bullhorn unit that includes a USB configuration port.

The USB device driver should be installed prior to connecting the Bullhorn unit to your computer. If the USB device driver is not installed and you connect the Bullhorn unit to the USB port on your computer, Windows displays the “Found New Hardware” message and icon in the System Tray of your computer. Windows will then attempt to locate a suitable device driver already installed on your computer. Exit any open windows and then complete the procedure in the next section to install the USB device driver.

Getting Started 9

http://www.microsoft.com


BATtools Suite InstallerThe BATtools Suite Installer (included in the installation kit) will install the UCT and all necessary support files. Before using BATtools Suite Installer, review the following information if a prior version of the UCT software is installed on your computer (see Figure 1-1). If a previous version of the UCT is not installed on your computer, continue with Installing the UCT and Support Files on page 12.

• Everyone Installation Option: If you installed a previous version of the UCT software using the Everyone option, the previous version must first be uninstalled prior to installing the new version.

• Just Me Installation Option: If you installed a previous version of the UCT software using the Just Me option, it is not necessary to uninstall the previous version prior to installing the new version.

Figure 1-1. Configuration Toolkit

The following procedure explains how to install the UCT software and support files from BATtools Suite Installer.

NOTE: If the installation media is unavailable, visit the BAT website Help menu (www.bullhornsys.com/wiki) and download the BATtools Suite Installer, which includes the UCT and all support files.Click Help > Downloads > BATtools Suite Installer.

Complete the following steps:

1 If a previous version of the software is installed using the installation option Everyone, uninstall the software as follows:

10 Getting Started

http://www.bullhornsys.com/wiki


a Click Start in the Windows Start menu and then select Settings > Control Panel.

b Click Add or Remove Programs.

c Click Configuration Toolkit and then click Remove.

d After the UCT software uninstalls, click the Windows close icon (X).

Getting Started 11


Installing the UCT and Support FilesTo install the UCT, Microsoft .NET Framework, and USB driver:

IMPORTANT: In order to install the USB device driver on your computer, you must log on as an administrator or your computer user name must be a member of the Administrators group. If needed, contact your network administrator or IT department to determine if your user name is setup with administrator rights or privileges.

1 Copy BATtools to your computer from either the media included in the configuration kit or the BAT website. Make sure that all files are extracted.

2 Open BATtools.zip file and double-click the BatToolsSuiteInstaller.exe file to begin the installation.

NOTE: During the installation process, you may be asked to restart your computer. Do not restart your computer until the BATtools Suite installation is complete.

3 Check the Universal Config Tool check box.

4 Check the Silicon Laboratories USB to UART Driver check box and the Microsoft .NET Framework check box, if available and unchecked. If either of these are already installed on your computer, a check box will not display next to the name.

NOTE: The MicroMaxProgrammer is included in the BATtools Suite Installer. You will not need to install this program.

5 Click the Install button.

NOTE: The battery/power cable does not need to be connected to the Bullhorn unit in order for Windows to recognize the Bullhorn USB connection. The Bullhorn USB connection draws power from the USB port on your computer.

6 Follow the prompts to install the programs.

12 Getting Started


WARNING: If you are installing the USB driver for the first time, the installation will ask if you want to restart your computer. Click No to continue the installation.

USB Driver Does Not InstallIf the UCT is unable to find your device, the USB driver may not have installed properly. An alternate method to install the USB driver is to install it directly from the executable (.exe) file. Follow the steps below:

1 Open the SI Labs folder on your computer.

2 Double-click the executable file CP210x_VCP_Win_XP_S2K3_Vista_7.exe.

3 Follow the prompts to install the driver.

Bullhorn Information LineThe Bullhorn Information Line is an automated attendant telephone system. It is typically used when installing units in the field. The system identifies when the last data transmission (or test packet) was received on your website account for a unit you specify.

Complete the following steps to use the Bullhorn Information Line:

1 Call the Bullhorn Information Line at 866-287-6739.

2 Press 1 to access the packet log when prompted.

3 Use your telephone keypad to enter the unit serial number when prompted. The unit serial number is included on the bar code label on the side of the unit. It is also included on the label of the shipping carton. If required, repeat this step to check another unit.

Getting Started 13


Contacting Technical ServicesIf you need assistance with the installation or configuration, contact American Innovations (AI) Technical Services in any of the following ways.

Telephone: Local: 512-249-3400Toll-free: 800-229-3404

Email: [email protected]

Address: American Innovations, Ltd.ATTN. Technical Services12211 Technology Blvd.Austin, TX 78727

Fax: 512-249-3444

14 Getting Started

2

RM4010 Installation

The procedures in this chapter explain how to install the RM4010.

WARNING: If the RM4010 is used in a manner not specified by American Innovations, the protection provided by the equipment may be impaired.

RM4010 OverviewThe RM4010 (Figure 2-1) is housed in a NEMA4X-rated weatherproof enclosure; designed primarily for cathodic protection applications; supports two-way communication with the BAT website using the SkyWave-Inmarsat satellite network, supports an optional relay connection for GPS synchronized current interruption, and provides six (6) configurable input channels with the following specifications:

• Input channels 1, 3 and 4: support analog (±5 V DC) or active digital.

• Input channel 2: supports analog (±100 V DC) or active digital.

• Input channels 5 and 6: support digital (0 - 15 V DC), active digital, or contact closure. Channel 5 can also be used as an accumulator, and channel 6 can be used as an accumulator reset.

15


IMPORTANT: To ensure consistent two-way communication, the satellite terminal must have a clear path pointing in the direction of the satellite with no obstructions between the two, such as buildings, trees, or hills.

Figure 2-1. RM4010 Hardware Configuration

(+)

(–)CH 1 Input

(+)(–)CH 2 Input

(+)

(–)CH 3 Input

(+)

(–)CH 4 Input

(+)

(–)CH 5 Input

(+)

(–)CH 6 Input

Switch Out / Relay(Interruption Only)

(+)(–)

Water-tight Fitting

1Front View

GPS Antenna

NOT IN USE

CH 6DIGITAL IN

CH 4

CH 2RectifierVOLTS+/-100VMAX

+–

+–

+–

RM4010

USBCONFIG

FIRMWAREUPLOAD

REPLACE WITHCOOPER BUSSMANN

ATC 3A FASTACTING FUSE

POWER IO

RADIO

PACKETQUEUE EMPTY

WAITINGSignal AcquiredAcquiring Signal

2

34

Input Channels (CH 1 – CH 6): See manual for input channel specifications.

Packet in Queue LED: Yellow when waiting to transmit packet; black when no packets waiting to transmit.

Switch Out (500mA max): Relay connection for rectifier current interruption. RM4010 supports mercury or solid state relay.

3 Amp Replaceable Fuse: AI recommends the Cooper Bussmann ATC-3 3 Amp fuse. Fuse filament appears broken when fuse is blown.

Radio LED: Red when acquiring satellite signal; green when signal acquired.

Satellite Terminal

– +

+–

SWITCHOUT500mA max

+–

CH 5DIGITAL IN

CH 3+–

CH 1+–

Legend:

2

Radio LED

Power Switch4

3

5

DC Power Input

Packet Queue LED6

7

1 Input Channels (CH 1-CH 6) and Relay Switch Out Input for Interruption Verification

USB Config Port

3 Amp Replaceable Fuse

5

6

7

NOTES:

DC INPUT10-14 VDC1.5A MAX

+/-15VMAX

+/-15VMAX

+/- 5VMAX

+/- 5VMAX

RectifierSHUNT+/- 5VMAX

Ground

8

8

16 RM4010 Installation


Figure 2-2. RM4010 Enclosure Connectors (bottom)

NOTE: Because of the variations in customer's installation and grounding methods, AI cannot warranty any damage to equipment caused by lightning strikes.

Preparing for the Installation

WARNING: Only accessories that meet American Innovation’s specifications may be used with the RM4010.

Use the following items as a checklist prior to installing the RM4010:

1 For information regarding safety symbols found on the unit, refer to Safety and Equipment Symbols on page 3.

2 American Innovations recommends using AI part number 211061-000 (Belden 5308UE), or an equivalent cable, for wiring inputs. Refer to Appendix A on page 99 for the technical specifications for this wiring.

Water tightfitting

Satellite terminal connector

GPS antenna connector

RM4010 Installation 17


3 Does the installation area provide enough room to easily open the enclosure? When you finish the installation, you will need to open the enclosure to configure the unit for service using the UCT software.

4 Is the latest version of the UCT software installed on the computer you plan to use during the installation? Refer to Universal Configuration Toolkit Software on page 8 for more information.

5 To ensure uninterrupted service, the location you plan to install the satellite terminal must meet the following qualifications:

• The area must be clear of all obstructions such as buildings, trees, and hills.

• The satellite terminal must have a clear line-of-sight pointing in the same direction as the satellite. To ensure consistent two-way communication, use the UCT software to determine which direction to point the satellite terminal.

Installing Conduit

IMPORTANT: If wires are to be buried or covered, use conduit to protect wires.

Install and dress conduit to protect wiring from physical damage, electrical interference, or weather. Conduit is provided by the customer.

Electrostatic DischargeElectrostatic Discharge (ESD) can damage electronic components. Provide ESD protection by wearing an antistatic wrist strap attached to any unpainted metal surface before opening the enclosure door of the unit or handling electronic parts. If an antistatic wrist strap is unavailable, discharge static electricity from yourself and your clothing by touching a nearby metal surface before opening the enclosure door of the unit or handling electronic components.



Ground ConnectionCommon practice is to ground the shield of the instrument cable at only one end. Instead, ground the shield drain wire to a suitable ground point at the source of the signal. This method is intended to drain off electrically induced voltage levels from external sources in an effort to ensure the most accurate and stable signal. The shield wire should never be grounded on both ends. If the signal has unacceptable fluctuation, the system ground should be repaired or improved.

Mounting RequirementsYou can mount the RM4010 enclosure anywhere, with a few precautions. The list below identifies conditions to consider when choosing a location. Mounting hardware is included with the enclosure.

Figure 2-3. RM4010 Enclosure Dimensions

Consider the following items when choosing a location to mount the enclosure:

• Mount the enclosure in a clear, unobstructed area.

• The area should provide enough working space to easily open the enclosure when performing routine maintenance or configuring the RM4010 for service using the UCT software.

Front View NOT IN USE

CH 6DIGITAL IN

CH 4+/– 5V

CH 2RectifierVOLTS

+–

+–

+–

RM4010

USBCONFIG

FIRMWAREUPLOAD

POWER IO

RADIO

PACKETQUEUE EMPTY

WAITING

Signal AcquiredAcquiring Signal

– +

+–

SWITCHOUT500mA max

+–

CH 5DIGITAL IN

CH 3+/– 5V

+–

CH 1Rectifier

AMPS

+–

6.5 inches(width) Depth: 4.5 inches

8.5 inches(length)

Cabinet Mounting Hole.31 inches diameter

(4 places)

12 inches(length)

DC INPUT10-14 VDC1.5A MAX

REPLACE WITHCOOPER BUSSMANN

ATC 3A FASTACTING FUSE



Installation Overview

WARNING: Turn off power to the rectifier before beginning any wiring installation to the RM4010.

The following steps provide an overview of a typical installation. The information also identifies the recommended installation sequence.

1 Determine where to install the RM4010, making sure objects or the terrain do not interfere with satellite communication.

IMPORTANT: Ensure that the equipment is positioned in such a manner that is it easily accessible to install, wire, and operate.

2 Mount enclosure (page 21) and then:

a Connect optional GPS antenna (page 22).

b Connect incoming power supply in DC Input connector of RM4010 (page 22).

c Install optional surge arrester and required ground (page 23).

3 Power up the RM4010 (see Figure 2-1 on page 16 for location of switch).

4 Connect configuration cable (page 25) and then:

a Start Universal Configuration Toolkit (UCT) software.

b Determine proper orientation of satellite terminal using the UCT software Satellite Setup Wizard.

5 Install satellite terminal (page 25); verify satellite signal using UCT software.

6 If using RM4010 to interrupt rectifier current, connect a Mercury or solid state relay to the RM4010 (page 28).

7 Connect your device(s) to RM4010 input channels; dress input wires inside enclosure (page 28).

8 Connect RM4010 input wires to output terminals of your device(s).

9 Configure RM4010 for service using UCT software (Chapter 4, RM4000 Series Configuration on page 77).



IMPORTANT: Electrostatic Discharge (ESD) can damage electronic components. Provide ESD protection by wearing an antistatic wrist strap attached to any unpainted metal surface before opening the enclosure door of the unit or handling electronic parts. If an antistatic wrist strap is unavailable, discharge static electricity from yourself and your clothing by touching a nearby metal surface before opening the enclosure door of the unit or handling electronic components.

Mounting the EnclosureThe following sections explain how to mount the RM4010 enclosure (Figure 2-3) on different types of surfaces. The unit’s enclosure includes a single factory-installed bracket for mounting on a pole or flat surface (Figure 2-4).

Figure 2-4. Mounting Bracket

NOTE: For an alternate mounting option, see Appendix C, .

Mounting the Enclosure on a Metal Pole or PipeThe enclosure comes with a mounting hardware kit that includes one (1) u-bolt , one (1) bolt, and mounting hardware (4 nuts and 4 washers for the u-bolt). The typical installation is on a free-standing metal pole or pipe using the included mounting hardware kit.

NOTE: The u-bolt used to mount the unit may be a maximum of 2-c” OD with 4-20.



Complete the following steps to install the RM4010 enclosure on a metal pole or pipe.

1 Run one u-bolt around the pole, through the pipe bracket, and then through the top of the mounting bracket. See Figure 2-4.

2 Slide a washer over and thread a nut onto each end of the u-bolt and tighten each nut.

3 Repeat steps 1 and 2 for the bottom of the mounting bracket.

NOTE: The enclosure can also be mounted on a flat surface using the attached mounting bracket or with optional, plastic mounting brackets. See Appendix C for instructions on using the plastic mounting brackets.

Installing the GPS AntennaComplete the following steps to install the optional magnetic-mount GPS antenna (Figure 2-1). The GPS antenna is used to synchronize rectifier current interruption.

1 Connect the antenna cable in the connector on the bottom of the RM4010 enclosure (see Figure 2-1 on page 16 for location).

2 Temporarily place the antenna on a metal surface, such as the rectifier enclosure.

Installing the Power Supply


Before beginning the power supply installation, take note of the following safety specifications:

• Any line-connected, single-pole switch with a marked OFF position shall be connected to a TERMINAL or lead intended for connection to the ungrounded conductor of the supply circuit.

• Overcurrent protective devices shall be connected to the ungrounded supply connector.



• A switch or circuit-breaker must be included in the installation.

• The switch must be suitably located and easily reached.

• The switch must be marked as the disconnecting device for the equipment.

• A multiple-pole circuit breaker shall interrupt all neutral and ungrounded connectors of mains supply simultaneously.

• Equipment intended for permanent connection to the mains shall have provisions for connection of a wiring system in accordance with ANSI/NFPA 70, NEC, with CSA C22.1, CEC, Part I, or with both, as appropriate.

Complete the following steps to install a power supply for the RM4010. Refer to Figure 2-1 on page 16 for location of power supply input connection.

1 Mount either the AC/DC or DC/DC power supply. Typically the power supply installs inside the rectifier enclosure.

2 Connect power supply AC Input or DC Input wires to the AC power source (neutral, white to white; and hot, black to black) or DC power source (positive to positive; and negative to negative).

3 Connect power supply DC Output wires to the DC Input connector on the faceplate of the RM4010.

4 Turn ON the RM4010 power switch.

NOTE: The RM4010 makes a clicking sound after turning on the power switch. This is a normal function and indicates the unit is polling input channels.

Installing the Surge Arrester (Optional)Complete the following steps to install the surge arrester (Figure 2-5). Also refer to the Surge Arrester - High Energy Quick Reference Guide (included with the surge arrester: part number 122186-000) for more details on the placement and installation.



Figure 2-5. High Energy Surge Arrester

1 Attach surge arrester’s black wires to the positive and negative terminals of the rectifier output.

2 Attach surge arrester’s white grounding wire to the rectifier, either by using an existing frame nut or with an I-beam ground clamp (Figure 2-6).

Figure 2-6. Grounding the Surge Arrester

Connecting Unit GroundComplete the following steps to ground the RM4010 to the rectifier frame.

1 Open RM4010 enclosure if closed.

2 Connect ground wire to RM4010 ground screw (marked with ground symbol, as shown to the left).

3 Connect ground wire to rectifier frame using spade connectors (Figure 2-7). You can connect in same place as the surge arrester.



Figure 2-7. Ground Wire with Spade Connectors

4 If necessary, use I-beam clamp to secure spade connectors. Remember to remove any paint where the clamp will be attached to the frame (Figure 2-8).

Figure 2-8. I-beam Ground Clamp and Spade Connectors for Ground Wire

Installing the Satellite TerminalThe following procedures explain how to determine the proper orientation of the satellite terminal; install the satellite terminal; and then verify satellite communications.

Find OrientationComplete the following steps to determine the proper orientation of the satellite terminal.

1 Connect the satellite terminal cable to the connector on the bottom of the RM4010 enclosure. See Figure 2-2 on page 17.

2 Turn ON the RM4010 power switch if the unit is not powered on.

3 Connect the provided configuration cable in the USB CONFIG port on the RM4010 (see Figure 2-1 on page 16 for location) and the other end of the cable in a USB port on your computer.

4 Start the UCT software. For more information, see the section Universal Configuration Toolkit Software beginning on page 8.



5 Verify GPS coordinates display in GPS Information of the main configuration window. If GPS coordinates do not display within a few minutes, complete the following steps to enter your location’s coordinates:

a Click Change in Communication Settings to display Satellite Setup Wizard.

b Follow the prompts to enter your location’s GPS coordinates and either accept the recommended satellite or choose another. When recommended Bearing (azimuth) and Elevation coordinates display, record the information for later use.

Install TerminalComplete the following steps to install the satellite terminal.

1 Install the satellite terminal on the mounting surface, such as a metal pole, using the provided mounting bracket (Figure 2-9). Ensure that the satellite terminal is facing skyward.

Figure 2-9. Satellite Terminal Mounting Bracket

2 Align the satellite terminal to the recommended angle:

a Loosen the bracket adjustment screws and loosen and remove angle position screws to move bracket (Figure 2-10).

b Tilt bracket until it is at the angle specific by the UCT. The holes will line up at the degree mark.

c Reinstall and tighten angle position screws and bracket adjustment screws to secure satellite.



Figure 2-10. Satellite Terminal and Bracket

3 Secure the GPS antenna.

VerifyUse the UCT software to verify the following information displays in Communication Settings.

1 Satellite status messages display in the following order: Not Available, Acquiring, and then Acquired.

NOTE: It should take less than two (2) minutes for the status message to change from Not Available to Acquiring. The status message Acquired displays when a link has been established with the satellite. Depending on satellite network activity, it may take up to eight (8) minutes for the RM4010 to establish a link with the satellite.

2 Signal Value is 18.5dB or better when a satellite link is Acquired.

3 If the satellite status message does not change to Acquired with a Signal Strength value of at least 18.5dB, complete the following steps:

a Verify the orientation of the satellite terminal.

b Verify objects or the terrain do not interfere with satellite communication. The satellite terminal’s view of the recommended satellite must be free of all line-of-sight obstructions.



c If required, click Change in Communication Settings to run Satellite Setup Wizard and select a different satellite.

IMPORTANT: If you are unable to establish a link with the satellite after choosing a different satellite and verifying the correct orientation of the satellite terminal, call Technical Support at 512-249-3400 (800-229-3404) for assistance.

Installing the Relay

NOTE: Please see the Mercury Relay Customer Advisory in Appendix D on page 109 regarding the manufacturer’s published limitations on mercury relays.

Complete the following steps to install the relay (mercury or solid state relay).

1 Identify the most suitable location and connection points for installing the relay. This may be in the secondary AC circuit, the DC positive (+) output, or DC negative (–) output.

2 Mount the relay on a suitable surface.

If you are installing the mercury relay, the relay functions with a contact in a pool of mercury, therefore making orientation of the relay important. Ensure that the relay is mounted in a vertical position (within 10 degrees from vertical) so that the writing on the relay is upright and readable.

3 Connect the appropriate cable for the load being switched, from the copper connectors on the bottom and top of the relay, to the connections points used earlier in step 1.

4 Connect relay wires in the Switch Out connector on the RM4010 (positive to positive; negative to negative).

Connecting Input Wires

WARNING: Ensure that power to the rectifier has been turned off before wiring the unit.



American Innovations recommends using AI part number 211061-000 (Belden 5308UE), or equivalent, for wiring inputs. Refer to Appendix A on page 99 for the technical specifications for this wiring.

Complete the following steps to connect input wires to the RM4010.

1 Connect your device(s) to the RM4010 using the information in the following list. Also refer to Figure 2-1 on page 16.

NOTE: To ensure a clean stable reading, keep field wiring as short as possible and use shielded twisted pair wire such as Alpha 2463C.

• Input channel 1: supports analog (±5 VDC) or active digital. When used in a cathodic protection application, the input channel is labeled CH 1 Rectifier AMPS.

• Input channel 2: supports analog (±100 VDC) or active digital. When used in a cathodic protection application, the input channel is labeled CH 2 Rectifier VOLTS.

• Input channels 3 and 4 (CH 3 and CH 4): support analog (±5 VDC) or active digital.

• Input channel 5 and 6 (CH 5 and CH 6): support 0 - 15 V DC digital, active digital, or contact closure. Channel 5 can also be used as an accumulator, and channel 6 can be used as an accumulator reset.

2 Dress input wires inside the RM4010 enclosure.

3 Connect RM4010 input wires to the output terminals of your device(s).

WARNING: If wires are to be buried or covered, conduit must be used to protect wires.

4 Tighten fitting on the bottom of the RM4010 enclosure.

5 If your device is turned off, turn ON the device to restore power to field wiring.

6 Continue with Chapter 6, RM4000 Series Configuration on page 77 to configure the RM4010 for service.




3

RM4011 Installation


RM4011 OverviewThe RM4011 (Figure 3-1) is housed in a NEMA-rated weatherproof enclosure; is designed primarily for cathodic protection applications; supports two-way communication with the BAT website using the SkyWave-Inmarsat satellite network; supports an optional relay connection for GPS synchronized current interruption; and provides six (6) configurable input channels with the following specifications:

• Input channel 1: supports analog (±5 VDC) or active digital. When used in a cathodic protection application, the input channel is labeled Ch 1 Rectifier AMPS.

• Input channel 2: supports analog (±100 VDC) or active digital. When used in a cathodic protection application, the input channel is labeled Ch 2 Rectifier VOLTS.

• Input channel 3 and 4: support analog (±5 VDC) or active digital.

• Input channel 5 and 6: support digital (0 - 15 V DC), active digital, or contact closure. Channel 5 can also be used as an accumulator, and channel 6 can be used as an accumulator reset.

31


IMPORTANT: To ensure consistent two-way communication, the satellite terminal must have a clear path pointing in the direction of the satellite with no obstructions between the two, such as buildings, trees, or hills.


(+)

(–)CH 1 Input

(+)(–)CH 2 Input

(+)

(–)CH 3 Input

(+)

(–)CH 4 Input

(+)

(–)CH 5 Input

(+)

(–)CH 6 Input

Switch Out / Relay(Interruption Only)

(+)(–)

Water-tight Fitting

1

Front View

GPS Antenna

2

Input Channels (CH 1 – CH 6): See manual for input channel specifications.


Switch Out (500mA max): Relay connection for for rectifier current interruption. RM4010 supports mercury or solid state relay.

3 Amp Replaceable Fuse: SLA fuse. Common fuse found at most automotive or electronic stores. Fuse filament appears broken when fuse is blown.


Satellite Terminal

Legend:1

2

Radio LED

Power Switch4

3

5

DC Power Input

Packet Queue LED6

7

Input Channels (CH 1-CH 6) and Relay Switch Out Input for Interruption VerificationUSB Config Port

3 Amp Replaceable Fuse

34

5

6

7

8

Ground8



Figure 3-2. RM4011 Enclosure Connectors


Preparing for the Installation

WARNING: Only accessories that meet American Innovation’s specifications may be used with the RM4011.

Use the following items as a checklist prior to installing the RM4011:

1 For information regarding safety symbols found on the unit, refer to ESD Precautions on page 2.

2 Will the unit be enclosed within the rectifier or will it need to be mounted outside the rectifier? Refer to Placement / Mounting Requirements on page 35 for more information.


Water tight fitting Satellite terminal connector

GPS antenna connector



4 To ensure uninterrupted service, the location you plan to install the satellite terminal must meet the following qualifications:


• The satellite terminal must have a clear line-of-sight pointing in the same direction as the satellite. To ensure consistent two-way communication, use the UCT software to determine which direction to point the satellite terminal.

Installing ConduitIf unit is installed outside the rectifier, install and dress conduit (not greater than 2”) to protect wiring from physical damage, electrical interference, or weather. Conduit is provided by the customer.

Electrostatic DischargeElectrostatic Discharge (ESD) can damage electronic components. Provide ESD protection by wearing an antistatic wrist strap attached to any unpainted metal surface before opening the enclosure door of the unit or handling electronic parts. If an antistatic wrist strap is unavailable, discharge static electricity from yourself and your clothing by touching a nearby metal surface before opening the enclosure door of the unit or handling electronic components.

Ground ConnectionCommon practice is to ground the shield of the instrument cable at only one end. Instead, ground the shield drain wire to a suitable ground point at the source of the signal. This method is intended to drain off electrically induced voltage levels from external sources in an effort to ensure the most accurate and stable signal. The shield wire should never be grounded on both ends. If the signal has unacceptable fluctuation, the system ground should be repaired or improved.



Placement / Mounting RequirementsYou can place or mount the RM4011 inside your rectifier or mount the unit outside the rectifier case. The list below identifies conditions to consider when choosing a location. Mounting brackets are included with the RM4011 for mounting inside/outside the rectifier. Other mounting hardware suitable for the type of mounting surface is provided by the customer.


Consider the following items when choosing a location to place or mount the enclosure:

• If the unit is to be placed inside the rectifier, enough room should be available to place the unit to the back or front of the case so that it is not directly over the air vent. Enough room will also be needed for input wires that will be routed from the unit.

• If the unit will be mounted outside the rectifier (for example, to the side of the rectifier case) or inside the rectifier, mounting brackets must be attached to the back of the enclosure. See Mounting the Enclosure - Optional on page 37 for more information. Also, conduit (not greater than 2”) must be used to protect input wires if the unit is mounted outside the rectifier case.

• The area should provide enough working space to easily open the enclosure when performing routine maintenance or configuring the RM4011 for service using the UCT software.

Front View

Depth: 3 inches4.75 inches(width)

6.75 inches(length)

1.25 inches(length)



Installation OverviewThe following steps provide an overview of a typical installation. The information also identifies the recommended installation sequence.

1 Determine where to place or mount the RM4011, making sure objects or the terrain do not interfere with satellite communication.

2 Remove enclosure cover.

NOTE: If mounting the enclosure outside rectifier, follow instructions in Mounting the Enclosure - Optional on page 37 before removing enclosure cover.

3 Connect optional GPS antenna (page 38).

4 Connect incoming power in DC Input connector of RM4011 (page 38).

5 Connect optional surge arrester and required ground wire (page 39).

6 Power on the RM4011 (see Figure 3-1 on page 32 for location of switch).

7 Connect configuration cable (see Figure 3-1 on page 32 for location of USB config port). and then:

a Start Universal Configuration Toolkit (UCT) software.

b Determine proper orientation of satellite terminal using the UCT software Satellite Setup Wizard.

8 Install satellite terminal (page 41); verify satellite signal using UCT software.

9 If using RM4011 to interrupt rectifier current, install and connect a Mercury or solid state relay to the RM4011 (page 43).

10 Connect your rectifier to RM4011 input channels; dress input wires inside enclosure (page 44).

11 Connect RM4011 input wires to output terminals of your rectifier (page 44).


13 Replace enclosure lid. If enclosure will be placed inside rectifier, place RM4011 to the rear or front, ensuring that the air vent is left as unobstructed as possible (for reference, see Figure 3-11 on page 45).




Mounting the Enclosure - OptionalThe following section explains how to mount the RM4011 enclosure, either inside or outside the rectifier case, using the optional mounting brackets (Figure 3-4).

Figure 3-4. Mounting Brackets Attached to Back of RM4011

Complete the following steps to mount the RM4011 enclosure using the four (4) plastic brackets from the accessory kit.

1 Use a Phillips head screwdriver to attach a mounting bracket to each corner of the enclosure as shown in Figure 3-4.

2 Place the enclosure against the flat surface where you will mount it.

3 Mark the mounting hole locations for the plastic brackets.

4 Set the enclosure out of the way.

5 Use a hand drill and a metal, masonry, or wood drilling bit to drill four holes into the mounting surface where you marked their locations in step 3.

6 Secure unit to mounting surface.



Installing the GPS AntennaComplete the following steps to install the optional magnetic-mount GPS antenna (Figure 3-1). The GPS antenna is used to synchronize rectifier current interruption.


1 Connect the antenna cable in the connector on the bottom of the RM4011 enclosure (see Figure 3-1 on page 32 for location of the connector).

2 Temporarily place the antenna on a metal surface, such as the rectifier enclosure. The antenna mounts on the satellite mounting bracket later (see Installing the Satellite Terminal on page 41).

Installing the Power Supply


Before beginning the power supply installation, take note of the following safety specifications:

• Any line-connected, single-pole switch with a marked OFF position shall be connected to a TERMINAL or lead intended for connection to the ungrounded conductor of the supply circuit.

• Overcurrent protective devices shall be connected to the ungrounded supply connector.

• A switch or circuit-breaker must be included in the installation.

• The switch must be suitably located and easily reached.

• The switch must be marked as the disconnecting device for the equipment.

• A multiple-pole circuit breaker shall interrupt all neutral and ungrounded connectors of mains supply simultaneously.

• Equipment intended for permanent connection to the mains shall have provisions for connection of a wiring system in accordance with ANSI/NFPA 70, NEC, with CSA C22.1, CEC, Part I or with both, as appropriate.

Complete the following steps to install a power supply for the RM4011. Refer to Figure 3-1 on page 32 for location of the power input connector.



1 Mount either the AC/DC or DC/DC power supply. Typically, the power supply installs inside the rectifier enclosure.

2 Connect power supply AC Input or DC Input wires to the AC power source (neutral, white to white; and hot, black to black) or DC power source (positive to positive; and negative to negative).

3 Remove RM4011 enclosure cover, if it was not removed earlier.

4 Connect power supply DC Output wires to the DC Input connector on the faceplate of the RM4011 (see Figure 3-1 on page 32 for location of connector).

5 Turn ON the RM4011 power switch.

NOTE: The RM4011 makes a clicking sound after turning on the power switch. This is a normal function and indicates the unit is polling input channels.








Installing GroundComplete the following steps to ground the RM4011 to the rectifier frame. Refer to Figure 3-1 on page 32 for the location of the ground connection on the RM4011.

1 Attach ground wire to the ground connection ( ) on the RM4011.

2 Connect other end of ground wire to rectifier frame using spade connectors (Figure 3-7).






Installing the Satellite TerminalThe following procedures explain how to determine the proper orientation of the satellite terminal; install the satellite terminal; and then verify satellite communications.

Find OrientationComplete the following steps to determine the proper orientation of the satellite terminal.

1 Connect the satellite terminal cable to the connector on the bottom of the RM4011 enclosure. See Figure 3-2 on page 33.

2 Turn ON the RM4011 power switch if the unit is not powered on.

3 Connect the provided configuration cable in the USB CONFIG port on the RM4011 (see Figure 3-1 on page 32 for location) and the other end of the cable in a USB port on your computer.

4 Start the UCT software. For more information, see the section Universal Configuration Toolkit Software beginning on page 8.

5 Verify GPS coordinates display in GPS Information of the main configuration window. If GPS coordinates do not display within a few minutes, complete the following steps to enter your location’s coordinates:

a Click Change in Communication Settings to display Satellite Setup Wizard.

b Follow the prompts to enter your location’s GPS coordinates and either accept the recommended satellite or choose another. When recommended Bearing (azimuth) and Elevation coordinates display, record the information for later use.



Install TerminalComplete the following steps to install the satellite terminal.

1 Install the satellite terminal on the mounting surface, such as a metal pole, using the provided mounting bracket (Figure 3-9). Ensure that the satellite terminal is facing skyward.

Figure 3-9. Satellite Terminal Mounting Bracket

2 Align the satellite terminal to the recommended angle:

a Loosen the bracket adjustment screws and loosen and remove angle position screws to move bracket (Figure 3-10).

b Tilt bracket until it is at the angle specific by the UCT. The holes will line up at the degree mark.

c Reinstall and tighten angle position screws and bracket adjustment screws to secure satellite.




3 Place the GPS antenna on the satellite terminal mounting bracket.

VerifyUse the UCT software to verify the following information displays in Communication Settings.

1 Satellite status messages display in the following order: Not Available, Acquiring, and then Acquired.

NOTE: It should take less than two (2) minutes for the status message to change from Not Available to Acquiring. The status message Acquired displays when a link has been established with the satellite. Depending on satellite network activity, it may take up to eight (8) minutes for the RM4011 to establish a link with the satellite.

2 Signal Value is 18.5dB or better when a satellite link is Acquired.

3 If the satellite status message does not change to Acquired with a Signal Strength value of at least 18.5dB, complete the following steps:

a Verify the orientation of the satellite terminal.

b Verify objects or the terrain do not interfere with satellite communication. The satellite terminal’s view of the recommended satellite must be free of all line-of-sight obstructions.

c If required, click Change in Communication Settings to run Satellite Setup Wizard and select a different satellite.

IMPORTANT: If you are unable to establish a link with the satellite after choosing a different satellite and verifying the correct orientation of the satellite terminal, call Technical Support at 512-249-3400 (800-229-3404) for assistance.

Installing the Relay

NOTE: Please see the Mercury Relay Customer Advisory in Appendix A on page 109 regarding the manufacturer’s published limitations on mercury relays.



Complete the following steps to install the relay (mercury or solid state relay).

1 Identify the most suitable location and connection points for installing the relay. This may be in the secondary AC circuit, the DC positive (+) output, or DC negative (–) output.

2 Mount the relay on a suitable surface.

If you are installing the mercury relay, the relay functions with a contact in a pool of mercury, therefore making orientation of the relay important. Ensure that the relay is mounted in a vertical position (within 10 degrees from vertical) so that the writing on the relay is upright and readable.

3 Connect the appropriate cable for the load being switched, from the copper connectors on the bottom and top of the relay, to the connections points used earlier in step 1.

4 Connect relay wires in the Switch Out connector on the RM4011 (positive to positive; negative to negative). See Figure 3-1 on page 32 for location of connector.

Connecting Input WiresComplete the following steps to connect input wires to the RM4011.

1 Connect your rectifier to the RM4011 using the information in the following list. Also refer to Figure 3-1 on page 32 for locations of input channel connections.

NOTE: To ensure a clean stable reading, keep field wiring as short as possible and use shielded twisted pair wire such as Alpha 2463C.


• Input channel 2: supports analog (±100 V DC) or active digital. .

• Input channel 3 and 4: support analog (±5 V DC) or active digital.

• Input channel 5 and 6: support digital (0 - 15 V DC), active digital, or contact closure. Channel 5 can also be used as an accumulator and channel 6 as an accumulator reset.

2 Dress input wires inside the RM4011 enclosure.



3 Connect RM4011 input wires to the output terminals of your rectifier.

WARNING: If wires are to be buried or covered, conduit must be used to protect wires.

4 Tighten fitting on the bottom of the RM4011 enclosure.

5 If rectifier is turned off, turn ON to restore power to field wiring.

6 Continue with Chapter 6, RM4000 Series Configuration on page 77 to configure the RM4011 for service.

7 After configuring the RM4011:

a Replace enclosure cover and secure.

b If the unit is to be placed inside the rectifier, place the unit to the front or rear of the rectifier case so that the unit covers only a minimal amount of the rectifier air vent (Figure 3-11).

Figure 3-11. RM4011 Placement Inside Rectifier Case - to Front




4

RM4013 Installation


RM4013 OverviewThe RM4013 (Figure 4-1) is housed in a NEMA-rated weatherproof enclosure; is primarily used in cathodic protection applications; uses the ORBCOMM satellite network for data transmissions; and includes 6 isolated input channels with the following specifications:

• Input channels 1, 3, and 4: support analog (±5VDC) or active digital.

• Input channel 2: supports analog (±100VDC) or active digital.

NOTE: Input channel 5 and 6: support digital, active digital, or contact closure. Channel 5 can also be used as an accumulator and channel 6 as an accumulator reset.

47




INPUT 1 (+ )

INPUT 1 ( – )

INPUT 2 ( – )

INPUT 2 (+ )

INPUT 3 ( – )

INPUT 3 (+ )

INPUT 4 ( – )

INPUT 4 (+ )

INPUT 5 ( – )

INPUT 5 (+ )

INPUT 6 ( – )

INPUT 6 (+ )

Solar PanelBattery Charger

(see Notes, below)

Water-tight Fitting

1

Front View

To satellite terminal

NOTINUSE

+–

CH6DIGITAL IN

CH4+/- 5V

CH2+/- 100V

CH5DIGITAL IN

CH3+/- 5V

CH1+/- 5V

+–

+–

+–

+–

+– RM4013

USBCONFIG

FIRMWAREUPLOAD

REPLACEWITH

3A FUSE

POWER IO

RADIO

PACKETQUEUE EMPTY

WAITING

Signal AcquiredAcquiring Signal

2

4

3

6

5

NOTES:Input Channels (CH1-CH6): See manual for input channel specifications.

Packet in Queue LED: Yellow when waiting to transmit packet; black when no packets waiting totransmit.

3 Amp Replaceable Fuse: AI recommends the Cooper Bussmann ATC-3 fuse. Fuse filament appears broken when fuse is blown.

Solar panel: For new solar panels with 3-pin connectors, connect to unit on bottom of enclosure. If using an existing solar panel, connect solar panel to Solar input connector on faceplate.


Legend:

Input Channels (CH1–CH6)1

2 USB Config Port

Power Switch4

Packet Queue LED

Radio LED5

3 Amp Replaceable Fuse3

6

7

Solar input7

8

Ground8




Preparing for the InstallationUse the following items as a checklist prior to installing an RM4013:

1 Does the installation area provide enough room to easily open the enclosure? When you finish the installation, you’ll need to open the enclosure to configure the unit for service using the UCT software.


3 To ensure uninterrupted service, the location you plan to install the antenna must meet the following qualifications:


• The antenna must have a clear line-of-sight facing in the same direction as the nearest ORBCOMM Gateway Control Center (GES). To determine which GES is closest to the installation site, visit the ORBCOMM website at http://www.orbcomm.com.

• The antenna must be installed at least two (2) feet above the solar panel to prevent signal interference during data transmissions.


http://www.orbcomm.com



Ground ConnectionCommon practice is to ground the shield of the instrument cable at only one end. Ground the shield drain wire to a suitable ground point at the source of the signal instead. This method is intended to drain off electrically induced voltage levels from external sources in an effort to ensure the most accurate and stable signal. The shield wire should never be grounded on both ends. If the signal has unacceptable fluctuation, the system ground should be repaired or improved.

Use the ground lug provided on the antenna/surge arrestor to connect the ground wire. Connect the other end of the ground wire to an earth grounding point. Use bare copper wire for the ground wire.

Installing Conduit



Mounting RequirementsYou can mount the RM4013 enclosure anywhere with a few precautions. Information in this section identifies conditions to consider when choosing a location. Mounting hardware suitable for the type of mounting surface is provided by the customer.


Front View 6.75 inches(length)

1.25 inches(length)




• Mount the enclosure in a clear, unobstructed area. The area should provide enough working space to easily open the enclosure when performing routine maintenance or configuring the RM4013 for service.

• The antenna must be installed at least two (2) feet above the solar panel and face in the same direction as the nearest ORBCOMM GES.


1 Determine where to install RM4013, making sure objects or the terrain do not interfere with satellite communication.

2 Mount the enclosure (page 52); install the antenna/surge arrestor (page 54); install the solar panel battery charger (page 56).

3 Connect the configuration cable in the USB CONFIG port of the RM4013 (see Figure 4-1 on page 48 for location). Connect the other end of the cable in a USB port on your computer.

4 Turn ON the RM4013 power switch (see Figure 4-1 on page 48 for location).

5 Run the UCT software to establish a communication link with the ORBCOMM satellite (page 58).

6 Connect the solar panel battery charger cable in the connector on the bottom of the RM4013 enclosure (page 58).

7 Connect your device(s) to RM4013 input channels; dress input wires inside the enclosure (page 58).

8 Connect a ground wire to the ground lug on the antenna/surge arrestor (page 58).

9 Connect RM4013 input wires to output terminals of your device(s) (page 58).





Mounting the EnclosureThe following sections explain how to mount the RM4013 enclosure (Figure 4-4). The enclosure includes a single factory-installed bracket for mounting on a metal pole, telephone pole, or similar surface.


Mounting the Enclosure on a Metal Pole or PipeThe enclosure comes with a pole mounting kit that includes two (2) u-bolts, two (2) pipe brackets, and mounting hardware (4 nuts and washers for the u-bolts).

The typical installation is on a free-standing metal pole or pipe using the included u-bolt kit to attach the enclosure to the pole or pipe.







NOTE: The enclosure can be mounted on a flat surface using the attached mounting bracket.

Alternate Mounting Method on a Flat SurfaceAn accessory kit (part number 370096-000, Mounting Rail Kit) is available for order to mount the enclosure against a flat surface. The kit includes 2 plastic mounting brackets (also called flanges, Figure 4-5) and mounting hardware (4 flat-head screws).

Complete the following steps to install the RM4013 enclosure on a flat surface using the plastic brackets from the optional accessory kit.

1 Use a 7/16 wrench to loosen the four (4) bolts securing the metal mounting bracket on the back of the enclosure, and then remove the bracket.

2 Place one of the two plastic mounting brackets (also called flanges) onto the back of the unit and drive two screws with a slotted screwdriver into the same holes that held the metal bracket in place.

Figure 4-5. Enclosure (Back View)

3 Repeat step 2 to attach the other plastic bracket.







8 Place the enclosure back in place where the holes line up and drive in lag bolts or other appropriate fasteners to hold the enclosure in place.

Installing the Antenna/Surge ArrestorComplete the following steps to mount the antenna bracket and install the antenna/surge arrestor.

1 Use two (2) lag bolts to mount the bracket on a pole or other type of mounting surface (Figure 4-6).

IMPORTANT: Mount the bracket in a position that allows the antenna to be located at least two (2) feet above the solar panel and facing in the same direction as the closest ORBCOMM GES. The antenna must have a clear line-of-sight with no obstructions, such as trees, hills, or buildings.

Figure 4-6. Antenna Mounting Bracket

2 From the bottom of the bracket, insert the brass mount (included with the antenna cable) in the mounting hole on the bracket.

Silicon Adhesive

Mounting Bracket

Antenna

Antenna Cable



3 From the top of the bracket, place the antenna on the brass mount and then twist the antenna clockwise to tighten.

4 Apply silicon adhesive around the base of the antenna to help secure it during high wind or other extreme weather conditions.



5 Connect the antenna/surge arrestor to the connector on the bottom of the enclosure (Figure 4-7).

Figure 4-7. Antenna/Surge Arrestor

Installing the Solar Panel Battery Charger (1.65 Watt)

The procedure in this section explains how to install the 1.65 watt solar panel battery charger. If you are working with the 5 watt solar panel battery charger instead, install the equipment using the manual (part no. 122119) provided in the installation kit.

NOTE: If you plan to use the optional AC Battery Charger instead of the solar panel battery charger, see Appendix C, Optional Equipment on page 105 for installation instructions.

IMPORTANT: Install the solar panel at least two (2) feet below the antenna to help prevent the solar panel from interfering with data transmissions.

Antenna with Surge ArrestorConnection

Solar PanelBattery ChargerConnection



Complete the following steps to install the solar panel battery charger.

1 Install the solar panel to a pole or flat surface using the attached bracket.

a If installing on a pole, install the u-bolt in the mounting holes on the pipe bracket as shown in Figure 4-8.

Figure 4-8. Solar Panel U-bolt and Pipe Bracket

NOTE: Figure 4-8 shows an example of an unregulated, 1.65 watt solar panel. A regulated solar panel is similar in appearance but includes a white cable and a regulator board wrapped in heat shrink tubing.

b Secure the u-bolt and pipe bracket on the frame bracket using two ¼-20 nuts and split-ring washers provided in the installation kit.

2 Tilt the solar panel angle bracket so the glass panel faces south for maximum sun exposure:

a Loosen bracket adjustment screws (see Figure 4-9).




b Loosen and remove angle set screws to adjust bracket angle.

c Tilt bracket to desired angle and reinstall and tighten angle set screws.

d Tighten bracket adjustment screws.

3 Connect the solar panel battery charger cable to the connector on the bottom of the enclosure (Figure 4-7).

Establish Communications with the ORBCOMM Satellite

Complete the following steps to establish communications with the satellite.

1 Open the enclosure to connect the configuration cable in the USB Config port on the faceplate of the RM4013 (Figure 4-1). Depending on the type of configuration cable, connect the other end of the cable in an available USB or RS232 serial port on your computer.

2 Turn ON the RM4013 power switch (Figure 4-1).

3 Start the UCT software. When the Find Devices window displays, select your RM4013.

NOTE: The UCT software begins to initialize. If the battery voltage is too low for normal operations, the status bar will freeze and the initialization process will not continue. Either recharge or replace the battery to continue.

4 Click Auto Update in the Communications group box when the main configuration window displays.

5 View the RADIO LED on the faceplate of the RM4013 (Figure 4-1) to confirm the unit is communicating with the ORBCOMM satellite. The LED is red when acquiring a satellite signal and then turns green when communication has been established.


IMPORTANT: To ensure a clean stable reading, keep field wiring as short as possible to maintain signal integrity and use shielded twisted pair wire such as Alpha 2463C.




1 If the input device has a voltage output, turn the device OFF to remove power from field wiring.

WARNING: If wires are to be buried or covered, conduit must be used to protect the wires.

2 Using the following information, route input wiring through the fitting on the bottom of the enclosure (Figure 4-1) and connect to input channels:

• CH1, CH3, CH4: analog (±5VDC) or active digital

• CH2: analog (±100VDC) or active digital

• CH5 Digital In: digital, accumulator, active digital, or contact closure

• CH6 Digital In: digital, active digital, accumulator reset, or contact closure

3 Using bare copper wire, connect a ground wire to the ground lug on the bottom of the antenna/surge arrestor. Ensure the other end of the ground wire connects to an earth grounding point.

4 Connect input wiring from the RM4013 to the output terminals of your device.

5 Dress input wires inside the RM4013 enclosure. To prevent damage to wiring, make sure input wires do not slip through the faceplate opening.

6 Tighten the fitting on the bottom of the RM4013 enclosure.

7 Turn ON the input device to restore power to field wiring.

8 Turn ON the RM4013 power switch (Figure 4-1) and then configure the unit for service using the information in Chapter 4, Appendix 6 on page 71.




5

RM4020 Installation


RM4020 OverviewThe RM4020 (Figure 5-1) is housed in a NEMA4X-rated weatherproof enclosure; is primarily used in cathodic protection applications; uses the ORBCOMM satellite network for data transmissions; and includes 6 isolated input channels with the following specifications:

• Input channels 1, 3, and 4: support analog (±5 V DC) or active digital.


• Input channel 5 and 6: support digital, active digital, or contact closure. Channel 5 can also be used as an accumulator and channel 6 as an accumulator reset.

61




INPUT 1 (+ )

INPUT 1 ( – )

INPUT 2 ( – )

INPUT 2 (+ )

INPUT 3 ( – )

INPUT 3 (+ )

INPUT 4 ( – )

INPUT 4 (+ )

INPUT 5 ( – )

INPUT 5 (+ )

INPUT 6 ( – )

INPUT 6 (+ )

Solar PanelBattery Charger

Water-tight Fitting

1

Front View

To Externally Mounted Antenna(see antenna note below)

NOTINUSE

+–

CH6DIGITAL IN

CH4+/- 5V

CH2+/- 100V

CH5DIGITAL IN

CH3+/- 5V

CH1+/- 5V

+–

+–

+–

+–

+– RM4020

USBCONFIG

FIRMWAREUPLOAD

REPLACEWITH

3A FUSE

POWER IO

RADIO

PACKETQUEUE EMPTY

WAITING

Signal AquiredAquiring Signal

2

4

3

6

5

NOTES:Input Channels (CH1-CH6): See manual for input channel specifications.


3 Amp Replaceable Fuse: AI recommends the Cooper Bussmann ATC-3 fuse. Fuse filament appears broken when fuse is blown.

Antenna: After installing the antenna on a suitable surface, apply silicon adhesive around the base of the antenna to help secure it during high wind or other extreme weather conditions.


Legend:

Input Channels (CH1–CH6)1

2 USB Config Port

Power Switch4

Packet Queue LED

Radio LED5

3 Amp Replaceable Fuse3

6

7

Ground7




Preparing for the InstallationUse the following items as a checklist prior to installing an RM4020:

1 Does the installation area provide enough room to easily open the enclosure? When you finish the installation, you’ll need to open the enclosure to configure the unit for service using the UCT software.


3 To ensure uninterrupted service, the location you plan to install the antenna must meet the following qualifications:


• The antenna must have a clear line-of-sight facing in the same direction as the nearest ORBCOMM Gateway Control Center (GES). To determine which GES is closest to the installation site, visit the ORBCOMM website at http://www.orbcomm.com.

• The antenna must be installed at least two (2) feet above the solar panel to prevent signal interference during data transmissions.

Water tight fitting Solar panel connector

Antenna connector





Ground ConnectionCommon practice is to ground the shield of the instrument cable at only one end. Ground the shield drain wire to a suitable ground point at the source of the signal instead. This method is intended to drain off electrically induced voltage levels from external sources in an effort to ensure the most accurate and stable signal. The shield wire should never be grounded on both ends. If the signal has unacceptable fluctuation, the system ground should be repaired or improved.

Use the ground lug provided on the antenna/surge arrester to connect the ground wire. Connect the other end of the ground wire to an earth grounding point. Use bare copper wire for the ground wire.

Installing Conduit





Mounting RequirementsYou can mount the RM4020 enclosure anywhere with a few precautions. Information in this section identifies conditions to consider when choosing a location. Mounting hardware is included with the enclosure.



• Mount the enclosure in a clear, unobstructed area. The area should provide enough working space to easily open the enclosure when performing routine maintenance or configuring the RM4020 for service.

• The antenna must be installed at least two (2) feet above the solar panel and face in the same direction as the nearest ORBCOMM GES.


1 Determine where to install RM4020, making sure objects or the terrain do not interfere with satellite communication.

2 Mount the enclosure (page 67); install the antenna/surge arrester (page 68).

Front View NOTINUSE

+–

CH6DIGITAL IN

CH4+/- 5V

CH2+/- 100V

CH5DIGITAL IN

CH3+/- 5V

CH1+/- 5V

+–

+–

+–

+–

+– RM4020

USBCONFIG

FIRMWAREUPLOAD

REPLACEWITH

3A FUSE

POWER IO

RADIO

PACKETQUEUE EMPTY

WAITING

Signal AquiredAquiring Signal

(Antenna not shown.)

Cabinet Mounting Hole.31 inches diameter

(4 places)6.5 inches

(width)

8.5 inches(length)

12 inches(length)

Depth: 4.5 inches



3 Install optional surge arrester and required ground (page 70).

4 Install the solar panel battery charger (page 72).

5 Connect the configuration cable in the USB CONFIG port of the RM4020 (see Figure 5-1 on page 62 for location). Connect the other end of the cable in a USB port on your computer.

6 Turn ON the RM4020 power switch (see Figure 5-1 on page 62 for location).

7 Run the UCT software to establish a communication link with the ORBCOMM satellite (page 74).

8 Connect the solar panel battery charger cable in the connector on the bottom of the RM4020 enclosure (page 74).

9 Connect your device(s) to RM4020 input channels; dress input wires inside the enclosure (page 74).

10 Connect a ground wire to the ground lug on the antenna/surge arrester (page 74).

11 Connect RM4020 input wires to output terminals of your device(s) (page 74).





Mounting the EnclosureThe following section explains how to mount the RM4020 enclosure. The enclosure includes a single factory-installed bracket (Figure 5-4) for mounting on a metal pole, telephone pole, or similar surface.


NOTE: For an alternate mounting option, see Appendix C, Optional Equipment on page 105.

Mounting the Enclosure on a Metal Pole or PipeThe enclosure comes with a mounting hardware kit that includes one (1) u-bolt , one (1) bolt, and mounting hardware (4 nuts and 4 washers for the u-bolt). The typical installation is on a free-standing metal pole or pipe using the included mounting hardware kit.

NOTE: The u-bolt used to mount the unit may be a maximum of 2-c” OD with 4-20.







NOTE: The enclosure can also be mounted on a flat surface using the attached mounting bracket or with optional, plastic mounting brackets. See Appendix C, Optional Equipment on page 105 for instructions on using the plastic mounting brackets.

Installing the Antenna/Surge ArresterComplete the following steps to mount the antenna bracket and install the antenna/surge arrester.

1 Use two (2) lag bolts to mount the bracket on a pole or other type of mounting surface (Figure 5-5).

IMPORTANT: Mount the bracket in a position that allows the antenna to be located at least two (2) feet above the solar panel and facing in the same direction as the closest ORBCOMM GES. The antenna must have a clear line-of-sight with no obstructions, such as trees, hills, or buildings.

Figure 5-5. Antenna Mounting Bracket

2 From the bottom of the bracket, insert the brass mount (included with the antenna cable) in the mounting hole on the bracket.

Silicon Adhesive

Mounting Bracket

Antenna

Antenna Cable



3 From the top of the bracket, place the antenna on the brass mount and then twist the antenna clockwise to tighten.

4 Apply silicon adhesive around the base of the antenna to help secure it during high wind or other extreme weather conditions.



5 Connect the antenna/surge arrester to the connector on the bottom of the enclosure (Figure 5-6).

Figure 5-6. Antenna/Surge Arrester





Antenna with Surge ArrestorConnection

Solar PanelBattery ChargerConnection




Connecting Unit GroundComplete the following steps to ground the RM4020 to the rectifier frame.

1 Open RM4020 enclosure if closed.

2 Connect ground wire to RM4020 ground screw (marked with ground symbol, as shown to the left).

3 Connect ground wire to rectifier frame using spade connectors (Figure 5-9). You can connect in same place as the surge arrester.






Installing the Solar Panel Battery Charger (1.65 Watt)

The procedure in this section explains how to install the 1.65 watt solar panel battery charger. If you are working with the 5 watt solar panel battery charger instead, install the equipment using the manual (part no. 122119) provided in the installation kit.

NOTE: If you plan to use the optional AC Battery Charger instead of the solar panel battery charger, see Appendix C, Optional Equipment on page 105 for installation instructions.

IMPORTANT: Install the solar panel at least two (2) feet below the antenna to help prevent the solar panel from interfering with data transmissions.



Complete the following steps to install the solar panel battery charger.

1 Install the solar panel to a pole or flat surface using the attached bracket.

a If installing on a pole, install the u-bolt in the mounting holes on the pipe bracket as shown in Figure 5-11.

Figure 5-11. Solar Panel U-bolt and Pipe Bracket

NOTE: Figure 5-11 shows an example of an unregulated, 1.65 watt solar panel. A regulated solar panel is similar in appearance but includes a white cable and a regulator board wrapped in heat shrink tubing.

b Secure the u-bolt and pipe bracket on the frame bracket using two ¼-20 nuts and split-ring washers provided in the installation kit.

2 Tilt the solar panel angle bracket so the glass panel faces south for maximum sun exposure:

a Loosen bracket adjustment screws (see Figure 5-12).




b Loosen and remove angle set screws to adjust bracket angle.

c Tilt bracket to desired angle and reinstall and tighten angle set screws.

d Tighten bracket adjustment screws.

3 Connect the solar panel battery charger cable to the connector on the bottom of the enclosure (Figure 5-6).

Establish Communications with the ORBCOMM Satellite

Complete the following steps to establish communications with the satellite.

1 Open the enclosure to connect the configuration cable in the USB Config port on the faceplate of the RM4020 (Figure 5-1). Depending on the type of configuration cable, connect the other end of the cable in an available USB or RS232 serial port on your computer.

2 Turn ON the RM4020 power switch (Figure 5-1).

3 Start the UCT software. When the Find Devices window displays, select your RM4020.

NOTE: The UCT software begins to initialize. If the battery voltage is too low for normal operations, the status bar will freeze and the initialization process will not continue. Either recharge or replace the battery to continue.

4 Click Auto Update in the Communications group box when the main configuration window displays.

5 View the RADIO LED on the faceplate of the RM4020 (Figure 5-1) to confirm the unit is communicating with the ORBCOMM satellite. The LED is red when acquiring a satellite signal and then turns green when communication has been established.


IMPORTANT: To ensure a clean stable reading, keep field wiring as short as possible to maintain signal integrity and use shielded twisted pair wire such as Alpha 2463C.




1 If the input device has a voltage output, turn the device OFF to remove power from field wiring.

WARNING: If wires are to be buried or covered, conduit must be used to protect the wires.

2 Using the following information, route input wiring through the fitting on the bottom of the enclosure (Figure 5-1) and connect to input channels:

• CH1, CH3, CH4: analog (±5 V DC) or active digital

• CH2: analog (±100 V DC) or active digital

• CH5 Digital In: digital, accumulator, active digital, or contact closure

• CH6 Digital In: digital, active digital, accumulator reset, or contact closure

3 Using bare copper wire, connect a ground wire to the ground lug on the bottom of the antenna/surge arrester. Ensure the other end of the ground wire connects to an earth grounding point.

4 Connect input wiring from the RM4020 to the output terminals of your device.

5 Dress input wires inside the RM4020 enclosure. To prevent damage to wiring, make sure input wires do not slip through the faceplate opening.

6 Tighten the fitting on the bottom of the RM4020 enclosure.

7 Turn ON the input device to restore power to field wiring.

8 Turn ON the RM4020 power switch (Figure 5-1) and then configure the unit for service using the information in Chapter 6, RM4000 Series Configuration on page 77.




6

RM4000 Series Configuration

IntroductionInformation in this chapter explains how to configure the RM4000 series units for service using the UCT software.

Configuration OverviewThe configuration process includes the following tasks:

1 If present, disable synchronization software, such as Microsoft® ActiveSync® (page 78).

2 Connect the unit to your computer. Start UCT and select a unit to configure (page 78).

3 Load a template if one is available for the unit type you plan to configure (page 81).

4 Choose a folder on your computer to store templates and log files (page 81).

5 Verify the default setting for International Gateway in Communications is correct (page 82).

6 Set up the controller clock and transmission schedule (page 83).

7 RM4010: set up interrupter information and power information such as battery installation date and AC outage delay parameters (pages 84-86).

RM4011: set up interrupter information and power information such as battery installation date and AC outage delay parameters (pages 84-86).

77


RM4013: set up battery information, such as the battery type and installation date (page 86).

RM4020: set up battery information, such as the battery type and installation date (page 86).

8 Set up input channels and alarms (page 88).

9 Transmit a test packet (page 97).

10 Save settings in the Event Log (page 97).

11 Save settings in a template (page 98).

Disable Synchronization SoftwareIf you use a synchronization software to synchronize a mobile device with your computer, temporarily disable the software before starting the UCT.

If you use Microsoft ActiveSync to synchronize the Allegro field computer with your computer, complete the following steps to temporarily disable the software:

1 Click Start > Programs > Microsoft ActiveSync.

2 Click File > Connection Settings. If enabled, click to remove the check mark and disable COM port, USB, and network options.

3 Click OK to close Connection Settings. Click File > Close to exit ActiveSync.

Connect the Unit and Start UCTComplete the following steps:

1 Connect the configuration cable in the USB port of your computer. Connect the other end of the cable in the USB CONFIG port on the front panel of the unit.

2 Double-click the UCT program icon on the desktop to start the UCT software. Or click Start > Programs > Configuration Toolkit.

78 RM4000 Series Conf iguration


3 Select a unit in the drop-down list of the Find Devices and then click Select (Figure 6-1).

Figure 6-1. Find Devices

4 The main configuration window displays. Press F2 to read unit settings and verify the unit and UCT software are communicating.

The following figures show examples of the main configuration window for the RM4010, RM4011, RM4013, and RM4020.

Figure 6-2. RM4010 Main Configuration Window

RM4000 Series Conf iguration 79







Load TemplateIf a template is available for the unit type you plan to configure, load the template using the following steps:

1 Click Tools > Advanced > Template > Load from Template.

2 When the Open Template window displays, locate the folder that contains the template. Select the template and then click Open.

3 After the UCT applies the template, press F2 to read settings or click Tools > Read Unit Settings. Click File > Save Current Setup in Event Log to save settings.

Choose Folder for Templates and Log FilesTemplates and log files store in My Documents by default. If you want to store these files in a different folder on your computer, complete the following steps:

1 Click Tools > Options to display the Options window.

2 Click Folder for Log files to display the Browse for folder window.



3 Select an existing folder or click Make New Folder to create a new folder.

4 Click Ok and then click Done to close the window.

Select SkyWave SatelliteRM4010/RM4011/RM4013

If you need to change the SkyWave satellite selection that was completed during the hardware installation, use the following steps to select a different satellite:

1 Click Change in Communication Settings.

2 Follow prompts in the Satellite Setup Wizard to select the appropriate SkyWave satellite.

3 Click Finish to exit the wizard and return to the main configuration window.

Select International GatewayRM4020

IMPORTANT: By default, International Gateway is set up for installations in the United States. The setting determines which Gateway Control Center (GCC) the RM4020 uses when transmitting data to your website account. If you are uncertain which setting to use, contact Technical Support for assistance.

If you need to change the default International Gateway selection, complete the following steps:

1 Click Change in Communication Settings to display the International Gateway window.

2 Select an option in the drop-down list and then click Accept.



Set Up Controller ClockThe controller clock is a time-of-day clock running inside the unit. It does not keep track of the month or year, or correct itself for daylight savings time. The unit uses the controller clock as a basis for all time-related operations.

Complete the following steps to set up the controller clock:

1 Click Change in Controller Clock .

2 Select a Controller time field. Use the up and down arrows to adjust the time. Repeat this step for remaining time fields as needed.

Or, click Set to PC Time if your computer is set up with the correct date and time in Windows Control Panel.

3 If you are working with the RM4010 or RM4011 and want to match a time zone, click the up or down arrow in the UTC Offset (h) field to subtract or add hours from Coordinated Universal Time (UTC), which is the same as Greenwich Mean Time. Click Save when you finish.

Set Up Transmission ScheduleTransmission schedule determines when and how often channel measurements transmit to your website account.


1 Click Change in Transmission Schedule to display the Transmission Schedule window.

2 Select a field in the Transmit report at field. Use the up and down arrows to adjust the time. Repeat this step for remaining time fields as needed.

3 If you want to include a delay in the transmission schedule, click Add Delay to place a check mark in the check box.

NOTE: Add Delay is based on the unit serial number. The unit serial number is equivalent to the number of seconds added to the reporting time. This feature is typically used to offset the transmission schedule for several units set up with the same reporting time.



4 Choose a repeat interval option in the And repeat every drop-down list.

5 Click Save.

Set Up Interrupter InformationRM4010/RM4011

Complete the following steps to set up the RM4010 or RM4011 in interrupter or interference mode:

1 Click Change in Interrupter Information on the main configuration window to display the Interruption Settings window (Figure 6-6).

Figure 6-6. Interruption Settings

2 To configure Interruption Settings, follow these steps:

a Click the down arrow in Interrupter Mode and select one of the following options: Daily, Start/Stop, or Continuous.



b If you selected Daily interrupter mode, complete the following steps to choose a time to start and stop the interruption:

• Type a time in the hours and minutes field of Start Time to select a time to start the interruption.

• Type a time in the hours and minutes field of Stop Time to select a time to stop the interruption.

You can also select a time field and then click the up or down arrow to adjust the time as needed.

c If you selected Start/Stop interrupter mode, type the month, day, and year in the Start Date and Stop Date fields to choose a date to start and stop the interruption.

Clicking the down arrow in the Start Date and Stop Date field displays a calendar where you can choose a date to start and stop the interruption.

d Set up interrupter On/Off Times in the following manner to indicate how many seconds the interrupter switches current on and off.

NOTE: On/Off Times can be set in 0.1 second increments, with the minimum cycle or period time being 0.2 seconds (on for 01 second/off for 0.1 second).

• Type the number of seconds in the On Time in Seconds fields to specify the amount of time current is switched on. If needed, click the up or down arrow to increase or decrease the number of seconds.

• Type the number of seconds in the Off Time in Seconds fields to specify the amount of time current is switched off. If needed, click the up or down arrow to increase or decrease the number of seconds.

e Set up Output and Synchronize Modes in the following manner:

• Output: If using a normally closed relay, click Normally Closed. If using a normally open relay instead, click Normally Open.

• Synchronize: If the interruption should start with the off cycle, click the option Off/On. If the interruption should start with the on cycle instead, click the option On/Off.

f Click Apply to save settings. Click Close or continue with the next step to set up optional Interference Mode Parameters.

3 Complete the following steps to set up optional Interference Mode Parameters:

a Click Interference Mode Enabled.



b Type a number in the # of Units field that represents the total number of interrupters used in the interference study. Click the up or down arrow to adjust the number of units as needed.

c Type a number in the Unit Number field that represents the RM4010 or RM4011 interrupter. For example, the RM4010 is interrupter #4 in a total of 10 interrupters used in the interference study.

d Type a delay time in seconds in the Delay Between Units field. Delay time is the number of seconds between the on and off cycle during interruption.

If needed, click the up or down arrow to increase or decrease the number of seconds.

e Click Apply to save settings and then click Close to close the window.

Set Up Power InformationRM4010/RM4011/RM4013

Complete the following steps to set up Power Information:

1 Click Change in Power Information on the main configuration window to display the Power/Battery window (Figure 6-7).

Figure 6-7. Power/Battery

2 Click Installed Today if the battery was installed today. Or, click the down arrow in Installed Date and use the calendar to choose an installation date.



3 Type the number of minutes in the AC Fails field to indicate the amount of time AC power must fail before an alarm packet transmits to your website account.

NOTE: Valid entries are in a range of 5 to 1440 minutes for the fields labeled AC Fails, AC Restored, AC Fails During Interruption, and AC Restored During Interruption. Use the up and down arrows to adjust the number of minutes as needed.

4 Type the number of minutes in the AC Restored field to indicate the amount of time AC power must be restored before an alarm packet transmits to your website account.

5 Type the number of minutes in the AC Fails During Interruption field to indicate the amount of time AC power must fail during interruption mode before an alarm packet transmits to your website account.

6 Type the number of minutes in the AC Restored During Interruption field to indicate the amount of time AC power must be restored during interruption mode before an alarm packet transmits to your website account.

7 Click Save to save settings and close the Power/Battery window.

Set Up Battery InformationRM4020

Complete the following steps to set up Battery Information:

1 Click Change in Battery Information on the main configuration window to display the Power/Battery window.

2 Click the down arrow in the Battery Type field and select an option from the list that matches the type of battery installed in the RM4020.

3 Click Installed Today if the battery was installed today. Or, click the down arrow in Installed Date and use the calendar to choose an installation date.

4 Click Save to save settings and close the Battery Information window.



Set Up Input Channels and AlarmsBased on the type of input device connected to the input channels of the unit, use the procedure in the following sections to set up channels and alarms:

• Set Up Input Channel for Analog Readings (page 88)

• Set Up Input Channel for Digital Readings (page 90)

• Set Up Channel 5 for Accumulator Readings (page 92)

Set Up Input Channel for Analog ReadingsComplete the following steps to set up channels 1, 2, 3, or 4 in analog mode. Refer to the Appendix F on page 113 for UCT field descriptions.

1 Based on the input channel the input device is connected to, click Ch1, Ch2, Ch3, or Ch4 in Channels on the main configuration window to display the channel configuration window (Figure 6-8).

For example, click Ch2 (channel 2) if the input device is connected to input channel 2 of the unit. Input channels 1, 2, 3, and 4 support ±5 V with channel 2 also supporting ±100V.

Figure 6-8. Example of Channel 2 (Ch2) Analog Settings



2 Click Enable and Analog to enable the channel for service and analog mode.

3 Based on the analog channel you are working with, complete one of the following steps:

a Channel 1, 3, or 4: click mV (millivolts) or Volts if the input device has a voltage output of ±5VDC.

b Channel 2: click +/– 5V or +/– 100V if the input device has a voltage output of ±5VDC or ±100VDC, respectively.

4 Type the unit of measurement used by the input device in the Engineering Units (on transducer) field.

5 Scale the input channel and input device as follows:

a Type the minimum and maximum voltage level supported by the input channel in the top and bottom fields of Raw voltage values (on unit input), respectively.

For example, to set up input channel 2 (Ch2) for rectifier voltage readings, type 0 in the top text box and 100 in the bottom text box. Or, to set up any of input channels 1, 2, 3, and 4 for pipe-to-soil readings, type –5 in the top text box and 5 in the bottom text box.

b Type the minimum and maximum voltage level supported by the input device in the top and bottom fields of Engineering Units (on transducer), respectively.

For example, to set up input channel 2 (Ch2) for rectifier voltage readings, type 0 in the top text box and 100 in the bottom text box. Or, to set up any of input channels 1, 2, 3, and 4 for pipe-to-soil readings, type –5 in the top text box and 5 in the bottom text box.

6 If you want to apply an optional response filter to the input channel, click the Response Filter Time button and select a time option.

7 If you want the unit to transmit an alarm packet when a low alarm condition occurs, click Transmit Low Alarm and then type a value in the Low Alarm field.

The unit transmits an alarm packet when the input channel reading is lower than the value entered in the Low Alarm field.



8 If you want the unit to continue transmitting low alarms until the alarm condition is removed in the field, click Repeat Low Alarm and then type a value in the Repeat delay in minutes field.

The Repeat delay in minutes value is the number of minutes between repeated alarm transmissions for both low and high alarm conditions.

9 If you want the unit to transmit an alarm packet when a high alarm condition occurs, click Transmit High Alarm and then type a value in the High Alarm field.

The unit transmits an alarm packet when the input channel reading is higher than the value entered in the High Alarm field.

10 If you want to include deadband in low and/or high alarms, type a value in the low and/or high alarm Deadband fields.

Valid entries are any positive scaled value that does not cause the alarm point to be lower than the minimum scale value or higher than the maximum scale value in Engineering Units (on transducer). Entering zero (0) disables deadband.

11 If you want to apply a persistence filter to low and/or high alarms, type a value in the Persistence field. Valid entries are any number from 1 to 65535. Entering zero (0) disables persistence.

12 Click Validate/Check Entries to verify configuration settings are correct and then click Save.

Text boxes display green or red to indicate whether or not an entered value is correct. If a text box is red, enter a different value and then validate again. If all text boxes are green, settings are correct.

Set Up Input Channel for Digital ReadingsThe procedure in this section explains how to set up any of channels 1 through 6 in digital mode. Input channels 1 through 6 support active digital mode. Channels 5 and 6 also support digital dry contact mode.

Refer to the Appendix F on page 113 for UCT field descriptions.



NOTE: The threshold value is 2 volts when input channels 1-4 are set up in active digital mode. If the input voltage is greater than 2 volts, an open state occurs. When less than 2 volts, a closed state occurs. When channel 5 or 6 is configured in active digital mode, the threshold value for these inputs is 1.5 volts. If the input voltage is greater than 1.5 volts, an open state occurs. When less than 1.5 volts, a closed state occurs.


1 Based on the input channel the input device is connected to, click Ch1, Ch2, Ch3, Ch4, Ch5, or Ch6 in Channels on the main configuration window to display the channel configuration window (Figure 6-9).

For example, click Ch3 (channel 3) if the input device is connected to input channel 3 of the unit.

Figure 6-9. Example of Channel 3 (Ch3) Digital Settings

2 Click Enable to enable the channel for service.

3 Click Active Digital or Digital Dry Contact. Only channels 5 and 6 support digital dry contact mode.

4 If you want to include an optional Debounce filter in alarm settings, type the number of seconds the input channel must remain in an alarm state before the unit transmits an alarm packet. If you want alarm states recognized immediately, enter zero (0) in the field.



5 If the channel is set up in Active Digital mode, complete the following steps to set up channel alarms:

a Click Transmit Low Alarm to have an alarm transmitted when the input voltage is lower than the threshold value.

b Click Transmit High Alarm to have an alarm transmitted when the input voltage is higher than the threshold value.

c Click Repeat Low Alarm and/or Repeat High Alarm if you want the unit to continue transmitting alarms until the alarm condition is removed in the field.

Type a value in the Repeat delay in minutes field that indicates the number of minutes between repeated alarm transmissions.

6 If channel 5 or 6 is set up in Digital Dry Contact mode, complete the following steps to set up channel alarms:

a Click Transmit Closed Alarm to have an alarm transmitted when the input device is in a closed state.

b Click Transmit Open Alarm to have an alarm transmitted when the input device is in a open state.

c Click Repeat Closed Alarm and/or Repeat Open Alarm if you want the unit to continue transmitting alarms until the alarm condition is removed in the field.




Set Up Channel 5 for Accumulator ReadingsIn order for the RM4010 and RM4011 accumulation rate to be once every 250 ms, the firmware version on these units must be 4.26. Verify the firmware version for the unit on the main configuration window, in the Unit Information pane. The current version is shown next to Controller Rev. (see Figure 6-10). If you need to update the firmware, please contact Technical Services (page 14).



Figure 6-10. RM4010/RM4011 Unit Information Pane - Controller Rev (Firmware Version)

The procedure in this section explains how to set up channel 5 for accumulator readings.

Refer to the Appendix F on page 113 for UCT field descriptions.


1 Click Ch5 in Channels on the main configuration window to display the channel 5 configuration window (Figure 6-11).

Figure 6-11. Example of Channel 5 (Ch5) Accumulator Settings

2 Click Digital Dry Contact if the unit will monitor open/closed states based on a digital contact closure. Or, click Active Digital if the unit will monitor open and closed states based on a voltage input.



3 If you want to include an optional Debounce filter in alarm settings, type the number of seconds the input channel must remain in an alarm state before the unit transmits an alarm packet. If you want alarm states recognized immediately, enter zero (0) in the field.

4 Type the current accumulator value showing on the input device in the Current Accumulator Value field.

5 If you want an alarm transmitted when the accumulated count reaches a certain value, type the value in the Accumulator Alarm Value field.

If you want the unit to transmit repeated alarms when the accumulator alarm is triggered, type the number of minutes between repeated alarms in the Repeat alarm frequency field.

6 Complete one of the following steps to reset the accumulated count to zero:

a Type a value in the Accumulator Reset Value field if you want to reset the count to zero (0) when channel 5 reaches a certain value.

–or–

b Click Reset on Low Alt Channel to have the accumulator reset to zero (0) when a low/closed state occurs on channel 6.

–or–

c Click Reset on High Alt Channel to have the accumulator reset to zero (0) when an a high/open state occurs on channel 6.

7 If channel 5 is set up in Active Digital mode, complete the following steps to set up channel alarms:

a Click Transmit Low Alarm to have an alarm transmitted when the input voltage is lower than the threshold value.

b Click Transmit High Alarm to have an alarm transmitted when the input voltage is higher than the threshold value.

c Click Repeat Low Alarm and/or Repeat High Alarm if you want the unit to continue transmitting alarms until the alarm condition is removed in the field.




8 If channel 5 is set up in Digital Dry Contact mode, complete the following steps to set up channel alarms:

a Click Transmit Closed Alarm to have an alarm transmitted when the input device is in a closed state.

b Click Transmit Open Alarm to have an alarm transmitted when the input device is in a open state.

c Click Repeat Closed Alarm and/or Repeat Open Alarm if you want the unit to continue transmitting alarms until the alarm condition is removed in the field.




Verify InterruptionRM4010/RM4011

To verify the RM4010 or RM4011 interrupter are ready for service, follow these steps:

1 If the Interruption Settings window (Figure 6-12) is not visible, click Change in Interrupter Information on the main configuration window.



Figure 6-12. Interruption Settings

2 Click Verify Interruption and then click Yes when the following message displays.

Figure 6-13. Interruption Verification Message

NOTE: The interruption verification process may take up to a minute to complete. The status message “Verifying interruption...” (along with the time remaining) displays at the bottom of the Interruption Settings window throughout the process.

3 Interruption verification is successful when the message “Interruption Verification Passed” displays in a window. Click OK to close the window.



4 If the message “Interruption Verification Failed” displays instead, complete the following steps:

a Verify Number of Satellites Tracked is 3 or more in GPS Information on the main configuration window. If not, relocate the magnetic-patch antenna in an area that provides sufficient satellites for communication.

b Verify incoming power is on. Interruption verification cannot be verified if the RM4010 or RM4011 are operating only with battery power. An AC or DC power source must be present.

c Repeat steps 1-3 to verify interruption. If interruption verification fails again, please call Technical Support for assistance.

Transmit a Test PacketTo transmit a test packet, click Transmit in Communication Settings on the main configuration window.

Status messages display in the window beside the Transmit button. When the status message Acknowledgement received from server appears, communication has been established.

IMPORTANT: If the status message Test Packet Return Transmission Failed appears, communication has not been established with the server. Click Transmit again to send another test packet. If communication cannot be established after several attempts, please call Technical Support for assistance.

Save Settings in the Event LogTo save configuration settings, click File > Save Current Setup in Event Log.

NOTE: The Event Log is used later when setting up the unit on the BAT remote monitoring website. The file saves on your hard drive in the same folder as the UCT software. The UCT software automatically assigns a file name using the unit serial number and .bhs extension.



Save Settings in a TemplateThe next procedure explains how to save settings in a template. You can use the template to set up another unit of the same type.


1 Click Tools > Advanced > Template > Save to Template to display the Save Template window.

2 Open an existing folder or create a new folder to store the template.

3 If you want to change the default file name of the template, type a name for the template in the File name field making sure to use the .bht file extension. Click Save when you finish.

Exit UCT and Close the EnclosureComplete the following steps:

1 Click File > Exit or press Alt+F4.

2 Disconnect the configuration cable from the unit and your computer.

3 Close and latch the enclosure door.

4 Tighten water-tight fittings on the bottom of the enclosure.

5 Re-enable any synchronization software disabled earlier in this chapter.

The installation and configuration are now complete.


A

Technical Specifications

This appendix includes technical specifications for the RM4010 and RM4011.

• Environmental conditions:

• Outdoor use only.

• Maximum altitude: 3,000 m.

• Temperature range: -30˚ C to +70˚ C.

• Maximum relative humidity: 95% at 45˚ C, decreasing linearly to 45% at 70˚ C.

• Minimum temperature rating for PCB (printed circuit board): at least 105˚ C.

• DC Input:

• Voltage: 10 - 14 V DC.

• Current: 1.5 A DC max.

• AC Input (requires optional external AC-DC power supply):

• Voltage: 100 - 240 V AC.

• Current: 0.15 - 0.3 A AC.

• Frequency range: 50 - 60 Hz.

• Battery:

99


• RM4010: Power Sonic PS-1230, 12 V, 3.4 AH, rechargeable, sealed lead acid battery (American Innovations part number 370042-000). Specified battery shall be used.

• RM4011: Power Sonic PS-1221S, 12 V, 2.0 AH rechargeable, sealed lead acid battery (American Innovations part number 370149-000). Specified battery shall be used.

• Switch Output: 0-12 V DC; 0.5 A DCmax source current.

• Analog CH1, CH3, and CH4: ±5 V DC.

• Analog CH2: ±100 V DC.

• Digital CH5 and CH6: 0 - 15 V DC.

• Scan Rate (accumulator): input sampled 16 times per second, with a minimum pulse width of 250 ms.

• Interconnect cable: Belden 5308UE; 300 Vrms; rated FT4; 600 V - 105˚ C, or equivalent.

• Fuse: Cooper Bussmann ATC-3, fast acting, blade type.

100 Technical Specif ications

B

Battery and Fuse Replacement

The procedure in this appendix explains how to replace the 12 volt lead acid battery in the RM4010, RM4011, and RM4020 and how to replace the fuse in the RM4010 and RM4011.

IMPORTANT: Turn off power from field wiring before performing either the battery replacement or fuse replacement procedures.

Replacing the Battery Complete the following steps:

1 Turn OFF power to remove power from field wiring.

WARNING: To prevent electrostatic discharge (ESD) damage when handling electronic equipment, always wear an antistatic wrist strap attached to an unpainted, grounded metal object. Ensure the wrist strap has maximum contact with bare skin. If an antistatic wrist strap is unavailable, discharge static electricity from yourself and your clothing by touching a grounded metal object before handling electronic equipment.

2 Open the enclosure door and turn OFF the power switch.

3 Disconnect input channel wiring.

101


4 Use a Phillips head screwdriver to loosen the four (4) screws securing the faceplate. Remove screws and set aside for reinstallation later. See Figure B-1.

Figure B-1. Remove Faceplate (RM4010/RM4011 (L) and RM4020 (R)

5 Lift up the faceplate and secure inside enclosure. You can also insert the top flange in the top groove inside the enclosure to secure faceplate. See Figure B-2.

Figure B-2. Secure Faceplate

Phillips Head Screw (4 places)

Phillips Head Screws(4 places)

Faceplate FlangeTop Groove

102 Battery and Fuse Replacement


6 Disconnect the red positive (+) and black negative (–) battery cables from the battery. See Figure B-2.

Figure B-3. Disconnect Battery Cables

7 Use a 3/8 inch nut driver to remove two (2) standoffs securing the battery bracket. Set the standoffs and battery bracket aside for reinstallation later.

8 Install the new battery. Secure the battery using the battery bracket and standoffs set aside earlier.

9 Reconnect the battery cables to the battery; positive to positive (red) and negative to negative (black).

10 Reinstall the faceplate using Phillips head screws set aside earlier.

11 Reconnect input channel wiring.

12 Turn ON the unit power switch and then close the door of the enclosure.

13 Turn power ON to restore power to field wiring.

The battery replacement is now complete.

Replacing the Fuse Complete the following steps to replace the fuse in the RM4010 and RM4011:

NOTE: American Innovations recommends the Cooper Bussmann ATC-3 fuse.

1 Turn OFF power to remove power from field wiring.

Disconnect postive and negative battery connections.

Battery and Fuse Replacement 103


WARNING: To prevent electrostatic discharge (ESD) damage when handling electronic equipment, always wear an antistatic wrist strap attached to an unpainted, grounded metal object. Ensure the wrist strap has maximum contact with bare skin. If an antistatic wrist strap is unavailable, discharge static electricity from yourself and your clothing by touching a grounded metal object before handling electronic equipment.

2 Open the enclosure door and turn OFF the power switch.

3 Remove old fuse. See Figure B-4.

Figure B-4. RM4010/RM4011 Fuse

4 Replace with new 3 amp fuse. Refer to Appendix A, Technical Specifications on page 99 for fuse recommendation and requirements.

5 Turn ON the unit power switch and then close the door of the enclosure.

6 Turn power ON to restore power to field wiring.

The fuse replacement is now complete.

104 Battery and Fuse Replacement

C

Optional Equipment

This appendix covers the following optional equipment for RM4000 Series units:

• AC battery charger kit - for recharging the battery.

• Plastic mounting hardware - replaces the metal mounting bracket to mount units on a flat surface.

AC Battery ChargerThe information in this section explains how to recharge the battery using one of the following optional AC battery charger kits (Figure C-1):

• Part No. 517137-000: AC battery charger kit for units that use the SkyWave satellite network, such as the RM4010, RM4011, and RM4013.

• Part No. 517173-000: AC battery charger kit for units that use the ORBCOMM satellite network, such as the RM4020.

105


Figure C-1. AC Battery Charger Kit


1 Use a small slotted screwdriver to remove two (2) screws on the AC battery charger (Figure C-1). Set screws aside for reinstallation later and then continue with step 2 (for RM4010, RM4011, or RM4013) 3or step 3 (for RM4020) .

2 If you are working with a unit that uses the SkyWave satellite such as the RM4010, RM4011, or RM4013, complete the following steps to recharge the battery:

a Route the battery charger cable through the liquid tight fitting and toward the battery inside the enclosure.

b Connect the red and red/black stripe wires to the battery in the following manner:

• Connect the red wire to the positive (+) terminal on the battery.

• Connect the red/black stripe wire to the negative (–) terminal on the battery.

c Connect the other end of the red and red/black stripe wires to the AC battery charger in the following manner:

• Connect the red wire to the positive (+) terminal on the AC battery charger. Secure wire using one (1) screw set aside earlier in step 1.

• Connect the red/black stripe wire to the negative (–) terminal on the AC battery charger. Secure wire using one (1) screw set aside earlier in step 1.

d Plug the AC battery charger in a 120 VAC power outlet.

The AC battery charger installation is now complete.

AC Battery Charger

Cable used with SkyWave satellite units; kit part no. 517137-000.

Cable used with GSM digital cellular units; kit part no. 517107-000.

Cable used with ORBCOMM satellite units; kit part no. 517173-000.

106 Optional Equipment


3 If you are working with a unit that uses the ORBCOMM satellite network, such as the RM4020, complete the following steps to recharge the battery:

a Plug the battery charger cable in the battery charger connector on the bottom of the enclosure. See Figure 5-2, page 63.

b Connect the other end of the battery charger cable to the AC battery charger in the following manner:

• Connect the white wire to the positive (+) terminal on the AC battery charger. Secure wire using one (1) screw set aside earlier in step 1.

• Connect the black wire to the negative (–) terminal on the AC battery charger. Secure wire using one (1) screw set aside earlier in step 1.

c Plug the AC battery charger in a 120 VAC power outlet.

The AC Battery Charger installation is now complete.

4 If you are working with a unit that uses the GSM digital cellular network, complete the following steps to recharge the battery:

a Plug the battery charger cable in the connector on the battery.

b Connect the other end of the battery charger cable to the AC battery charger in the following manner:

• Connect the white wire to the positive (+) terminal on the AC battery charger. Secure wire using one (1) screw set aside earlier in step 1.

• Connect the black wire to the negative (–) terminal on the AC battery charger. Secure wire using one (1) screw set aside earlier in step 1.

c Plug the AC battery charger in a 120 VAC power outlet.

The AC battery charger installation is now complete.

Mounting on a Flat SurfaceAn accessory kit (part number 370096-000, Mounting Rail Kit) is available for order to mount the enclosure against a flat surface. The kit includes 2 plastic mounting brackets (also called flanges, Figure C-2) and mounting hardware (4 flat-head screws).

Complete the following steps to install the enclosure on a flat surface using the plastic brackets from the optional accessory kit.

1 Use a 7/16 wrench to loosen the four (4) bolts securing the metal mounting bracket on the back of the enclosure, and then remove the bracket.

Optional Equipment 107


2 Place one of the two plastic mounting brackets (also called flanges) onto the back of the unit and drive two screws with a slotted screwdriver into the same holes that held the metal bracket in place.

Figure C-2. Enclosure (Back View)

3 Repeat step 2 to attach the other plastic bracket.





8 Place the enclosure back in place where the holes line up and drive in lag bolts or other appropriate fasteners to hold the enclosure in place.

108 Optional Equipment

D

Mercury Relay Customer Advisory

Mercury Relay Customer AdvisoryThe information in this section is intended to notify American Innovations (AI) customers of the manufacturer’s published limitations on mercury relays.

Customers primarily purchase mercury relays for use with current interrupters. Current interrupters provide great programming flexibility to enable customers to use a wide variety of interruption cycles.

AI supplies mercury relays from a variety of respected and reliable vendors including MDI and American Electronic Components (AEC). These manufacturers publish expected relay lives of 3 to 6 million cycles depending upon the type of relay selected. AEC, the manufacturer of Durakool relays, indicates that relay life will be significantly shortened at rates exceeding 1,500 cycles per hour. MDI recommends no more than 900 cycles per hour. Depending upon the interruption cycle chosen by the customer, it is possible to exceed the manufacturer’s recommendation, which would result in a likely reduction of service life.

As an example, customers who elect to use mercury relays to interrupt at 1 cycle per second will generate 3600 cycles per hour. Customers should consult the manufacturer’s documentation to select the appropriate relay for the application.

Durakool information can be found on the AEC web page at the following address:

http://www.aecsensors.com/html

109

http://www.aecsensors.com/html


In the Durakool documentation, the following two situations are explained that may impact the current carrying capacity of the relay: 1) cycle rate and 2) voltage values. The sizing tables indicate a methodology for determining the maximum amperage that can be carried depending upon the cycle rate. An additional de-rating table for mercury relays is provided for those instances where voltage in excess of 48 V DC is being interrupted. When selecting relays, customers should be aware of both of these de-rating tables to choose the best relay for the application.

To avoid depolarization of the CP system, the mercury relays we sell that AI sells are of the normally closed variety. It is possible that a normally closed relay will fail at the end of its life in the open position due to a malfunction of the spring mechanism which drives the plunger/contacts into a normally closed position. If this occurs, a depolarization situation would result. AI has the following two recommendations:

1 Customers using mercury relays should consider periodic replacement of these relays based upon engineering estimated life via a preventive maintenance program to reduce the likelihood of an open circuit failure.

2 If fast cycle operation is common, AI recommends a solid state relay for maximum life and reliability.

Although most interrupters are capable of being programmed for faster interruption cycles, AI recommends that customers not exceed 900 cycles per hour (or a cycle time of less than four seconds) and will not warranty devices that are utilized in this manner. AI adds a serial number to relays that is supplied that we supply to enable the tracking of the shipment date. The approximate age of the relay may be used to assist AI in return material response, failure analysis, and warranty claims. Manufacturers will be consulted to help determine failure cause and to advise customers that warranties may not be honored if it is deemed that the mercury relay is used outside of recommended parameters.

If you have questions or need additional information, please contact Technical Support (800-299-3404). Office hours are Monday–Friday, 8:30–5:00 Central Time.

110 Mercury Relay Customer Advisory

E

Regulatory Notices

FCC RequirementsThe following FCC requirements are met by the products described in this guide.

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment in an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

111


Export Control Classification NumberThe Export Control Classification Number (ECCN) assigned to the Bullhorn Universal Configuration Toolkit (UCT) software by the U.S. Bureau of Industry and Security (BIS) is as follows:

• ECCN Classification: No Classification

• ECCN Code: EAR99 or NLR

112 Regulatory Notices

F

Glossary

The following information is an alphabetical list of technical terms and UCT software fields identified in this manual.

Table F-1. Glossary of Technical Terms

Term Definition

Auto Update Clicking Auto Update in Communication Settings on the main configuration window displays a “live” RSSI reading. Also see Update.

Clicking Auto Update in Channels on the main configuration window automatically displays “live” input channel readings every 16 seconds.

Bat/Solar/DC Voltages Information field in Power Information showing the battery and DC voltage levels for the unit. Information in this field updates when you start the UCT software or press F2 to read unit settings.

Controller Clock Time-of-day clock running inside the unit. The clock is used for all time-related operations such as transmission schedules.

Controller Rev Firmware version of the controller board installed in the unit.

113


Deadband Deadband applies hysteresis to low and high alarm values. It is an area of equal value above and below the alarm values. When the input voltage passes below the deadband area, this is the alarm point that triggers a low alarm transmission. Likewise, when the input voltage passes above the deadband area, this is the alarm point that triggers a high alarm transmission.

Debounce filter Debounce is an optional filter that applies to alarms. The filter uses the entered value as the number of seconds an input channel must remain in an alarm state before the unit transmits an alarm. The purpose of the filter is to prevent short spurious noise pulses from triggering an alarm. If the input channel goes out of alarm during the polling cycle, the unit resets and does not transmit an alarm. When Debounce is set to zero (0), no filter is applied and the alarm state is recognized immediately.

GPS Global Positioning System. Global navigation satellite system that provides location and time information when three or more GPS satellites are in view.

GPS Information Information field showing unit GPS and elevation coordinates. Antenna Status applies to the magnetic-mount antenna, and Number of Satellites Tracked applies to the SkyWave satellite terminal.

HI, HI Rpt, LO, LO Rpt Abbreviations for alarm labels high, high repeat, low, and low repeat, respectively.

IMEI International Mobile Equipment Identity. Unique number assigned to the digital cellular radio by the manufacturer for identification purposes.

International Gateway Gateway Control Center (GCC) used by the RM4010, RM4011, and RM4020 for communication with the satellite network (ORBCOMM or SkyWave-Inmarsat).

Interruption Verification See Verify Interruption.

LED Light Emitting Diode. Status indicator.

Table F-1. Glossary of Technical Terms (continued)

Term Definition

114 Glossary


LinkQ See RSSI.

Persistence Persistence is the number of samples an input channel must complete while in a particular state before that state is recognized as an alarm.

For example, if an input channel is set up with a high alarm and a persistence value of 5, the input channel must complete 6 samples in a high state before it is recognized as a high alarm.

Polling Cycle Polling cycle refers to how often the unit scans or reads input channels. UCT scans input channels at regular intervals based on the hardware sampling of the unit type.

Radio ISN Radio Identification Serial Number. The SkyWave satellite terminal and unit ship from the factory as a matching pair. Both are assigned the same ISN at the factory for identification purposes. Also see Unit ISN.

Radio Version Version number assigned to an analog cellular radio by the manufacturer. The UCT software displays “n/a” (not applicable, not available) for digital cellular and satellite unit types such as RM4010, RM4011, and RM4020.

Response Filter Time Optional filter for input channels set up in analog mode. The response filter slows the unit’s response to sudden changes in the input signal. The purpose of the filter is to help eliminate false alarm transmissions in unstable environments that have a tendency to produce temporary noise

Input channels include hardware filters suitable for rectifier outputs such as those used in line-powered CP systems. Response Filter Time applies a response time to the input channel in addition to a hardware filter response. Actual response time may vary based on variables such as the current input voltage level and position of the unit’s polling cycle.


Term Definition

Glossary 115


RSSI Receive Signal Strength Indicator. RSSI value and green or red status bar are static indicators of the last RSSI reading. Clicking Auto Update forces the UCT to display a “live” RSSI reading. Based on the type of communication network used by the unit, the RSSI value should meet the following qualifications:

• KORE Telematics (GSM): unit requires an RSSI greater than –88dB. RSSI is on a negative scale. Numbers closer to zero indicate a stronger signal.

• SkyWave Mobile Communications: RM4010 and RM4011 use an RSSI scale of 0.00dB to 50.00dB. RSSI of 14dB and higher indicates a strong signal; levels below 14dB indicate no satellite communication.

• ORBCOMM: RM4020 uses an RSSI scale of 0.0 to 15.0. Levels above 12 indicate a strong signal; levels below 8 indicate no satellite communication. RSSI is also referred to as LinkQ in the UCT software.

Serial No. Unique serial number assigned to the unit at the factory for identification purposes.

SIM Subscriber Identity Module. Unique identification number assigned to the digital cellular radio by the service provider.

Status Indicators UCT software includes the following three (3) status indicators in the bottom, right hand side of the main configuration window:

• Green/red indicator: Green indicator remains lit when running UCT. After transmitting a test packet, green indicator begins flashing. Green indicator changes to a flashing red indicator when communication cannot be established with the network.

• Yellow indicator: Flashes when unit transmits data.

• Black indicator: Not currently used.

Transmission Schedule Scheduled data transmission at regular time intervals.


Term Definition

116 Glossary


Transmit Click the Transmit button to force the unit to send a test packet for communications testing. Status messages display beside the button to describe the process, such as Test Packet Status, Preparing, and Sending test packet.

Transmit Retries Number of times the unit resends a data or alarm packet when an acknowledgment is not received from the communication network.

UCT Universal Configuration Toolkit. Software program used to configure a unit for service and view status information such as channel measurements, battery voltage level, and RSSI.

Unit ISN Unit Identification Serial Number. The unit and SkyWave satellite terminal ship from the factory as a matching pair. Both are assigned the same ISN at the factory for identification purposes. This field applies to RM4010 or RM4011. Also see Radio ISN.

Update Click Update in Channels on the main configuration window to display a “live” reading of all enabled input channels. Also see Auto Update.

USB Universal Serial Bus. Communication protocol used by a computer for communications with an externally connected device.

Verify Interruption Applies to RM4010 and RM4011 only. During interruption verification, the UCT software verifies 3 or more satellites are in view and the external relay switches from off to on. If less than 3 satellites are in view, or the AC or DC power source is not functional, or the external relay does not switch from off to on, interruption verification has failed.


Term Definition

Glossary 117


118 Glossary

Index

Symbols.NET Framework 9

AAC/DC power supply

RM4010 23RM4011 38

Accumulator 31readings 93reset 31reset, RM4010 15RM4010 15

ActiveSync 78Administrator

privileges 12rights 12

Alarms 88Analog readings 88Antenna

installation, RM4020 49, 63surge arrestor, RM4020 56

Antenna/surge arresterRM4020 68

Antenna/surge arrestorRM4020 54

Antistatic wrist strap 2, 101, 104Asset Tracker website 1, 4, 5Auto update 117

BBattery

backup 6replacement 6

Battery installation date 86Battery replacement 101Battery type 86BATtools

installing 12Branch circuit protection 6Bullhorn information line 13

CCathodic protection 15, 31, 47, 61Caution symbol 4Channel setup 88Circuit-breaker 23Conduit

RM4010 18RM4020 64

Controller clock 83, 113Current interrupter

RM4010 20RM4011 36

DDC/DC power supply

RM4010 23RM4011 39

Deadband 114Debounce filter 91, 114Device driver

administrator 12installing 12

Digital threshold value 91

EEarth ground 3Earth ground point 50, 64ECCN code 112Electrostatic Discharge 18, 21, 34, 37,52, 66Enclosure

dimensions RM4010 19dimensions RM4011 35dimensions RM4020 50, 65mounting RM4010 19mounting RM4011 35mounting RM4020 50, 65

Equipment symbols 3Equipment warranty 17, 33, 48, 62ESD 21, 37, 52, 66

119


ESD precautions 2, 101, 104Event log 97

FFind devices 78Found new hardware 12Fuse 6

replaceable, RM4010 16replaceable, RM4011 32replaceable, RM4020 48, 62replacement 101RM4010 16RM4011 32RM4020 48, 62

GGateway Control Center

RM4020 49, 63Gateway control center 82GPS

required satellites 97GPS antenna

RM4010 20, 22RM4011 36, 38

GPS satellite fix 97Ground

earth 50, 64Ground connection 19, 34

RM4020 50, 64Ground lug

RM4020 59, 75Ground wire

RM4020 51, 59, 66, 75

IIMEI 114Incoming power

DC input, RM4010 20DC input, RM4011 36

Input channelsRM4010 29RM4011 31, 44RM4020 47, 61

Input device wiringRM4010 29RM4011 44

RM4020 74Installation

RM4010 overview 20RM4011 overview 36RM4020 overview 47, 61

Installation site qualificationsRM4010 17RM4011 33RM4020 49, 63

International gateway 82, 114Interrupter

interference mode 85RM4010 20RM4011 36

LLED

packet queue, RM4010 16packet queue, RM4011 32packet queue, RM4020 48, 62radio, RM4010 16radio, RM4011 32radio, RM4020 48, 62RM4010 16RM4011 32RM4020 48, 62

Lightning strikes 17, 33, 48, 62Line of sight

satellite terminal 18, 34LinkQ 115Lithium battery 2

MMercury relay 20, 36

customer advisory 109

OORBCOMM GES

RM4020 49, 63ORBCOMM satellite

communication link 58, 74Overcurrent protection

20 amp fuse 6branch circuit protection 6circuit breaker 6

Overcurrent protection device 6

120


PPacket

transmit 83Packet Queue LED

RM4010 16RM4011 32RM4020 48, 62

Persistence 115Polling cycle 115Power disconnect 6

external overcurrent protectiondevice 6

overcurrent protection device 6Power supply

AC/DC, RM4010 23AC/DC, RM4011 39DC/DC, RM4010 23DC/DC, RM4011 39safety specifications 22standards 23

RRadio ISN 115Radio LED

RM4010 16RM4011 32RM4020 48, 62

Read unit settings 79Rectifier Amps 31Rectifier current interruption 36

RM4010 20Rectifier Volts 31Relay

installation, RM4010 28installation, RM4011 44Mercury 20, 36normally closed 85normally open 85solid state 20, 36

Relay inputRM4010 16RM4011 32

Replacement battery 6Replacing

battery 101fuse 101

Response filter 115

RM4000 Seriesspecifications 5

RM4010conduit installation 18enclosure dimensions 19enclosure installation 21GPS antenna installation 22grounding 24hardware configuration 16input channels 15input wires installation 28installation overview 20installation preparation 17overview 15power supply installation 22rectifier current interruption 20relay installation 28satellite terminal installation 25surge arrester installation 23

RM4011conduit installation 34GPS antenna installation 38hardware configuration 32input channels 31input wires installation 44installation overview 36installation preparation 33installing ground 40optional enclosure mounting 37optional mounting brackets 37overview 31power supply installation 38rectifier current interruption 36relay installation 43satellite terminal installation 41surge arrester installation 39

RM4020antenna installation 54, 68antenna/surge arrester connec-

tion 70antenna/surge arrester installa-

tion 68antenna/surge arrestor installa-

tion 54conduit installation 50, 64enclosure dimensions 50, 65enclosure installation 50, 52, 65,

67establishing communications 58,

121


74ground connection 50, 64grounding 71hardware configuration 48, 62input channel specs 59, 75input channels 47, 61input wires installation 58, 74installation overview 51, 65installation preparation 49, 63overview 47, 61solar panel installation 56, 72surge arrester installation 70surge arrestor connection 56

RSSI 116GSM unit 116ORB unit 116SAT unit 116

SSafety symbols 3Satellite

SkyWave 15, 31Satellite setup wizard 20, 36Satellite signal strength

RM4010 25RM4011 41

Satellite statusacquiring, RM4010 27acquiring, RM4011 43not available, RM4010 27not available, RM4011 43

Satellite terminaldirection 32installation, RM4010 25installation, RM4011 41line of sight 18line of sight, RM4011 34proper orientation, RM4010 25proper orientation, RM4011 41RM4010 16

Serial numberunit 116

SIM 116Site survey

RM4010 17RM4011 33RM4020 49, 63

SkyWave satellite selection 82

SkyWave-Inmarsat satellite 15, 31Solar panel

RM4020 56, 72Solid state relay 20, 36Specifications

RM4000 units 5Status indicator 114, 116Surge arrester

ground lug, RM4020 75RM4010 23RM4011 39RM4020 70

Surge arrestorground lug, RM4020 59RM4020 54, 56

Symbolscaution 4equipment 3off supply 4on supply 4safety 3

TTechnical support 14Template

folder 81load 81saving 98

Test packet 117transmit 97

Threshold value 91Transmission schedule 83, 116Transmit packet 83, 117Transmit retries 117Two-way communication

RM4010 15RM4011 31

UU-bolt Mounting

RM4010 21RM4020 52, 67

UCT 1, 36, 117installing 10See also Universal Configuration

Toolkitstarting 78

122


Universal Configuration Toolkit 1, 8, 36See also UCT

Updateauto update 117

USB 117USB Config port

RM4010 16RM4011 32

RM4020 48, 62USB device driver 9

WWarning

symbol 4Warning symbol 4

123


124