Badger Meter ORION Classic (CE) - Manual (Page 14)

ORION® Water Endpoints
USING GEL CAPS TO CONNECT AN ENCODER
For those connections that are not factory wired or equipped with in-line connectors, follow these guidelines for using gel
caps when splicing is required, either for installation or to fix a repair after a tamper .
Refer to the wiring charts starting on
page 9 .
NOTE: N
• For pit environments, splice connections require a field splice kit (62084-001), which can be ordered separately . Refer
to the instructions found in the document, Field Splice Kit for Badger Meter AMR/AMI Products, which is available at
www.badgermeter.com .
• For all installations, excess wire should be coiled and cable tied to avoid any damage .
• Required splicing tools are shown here .
Splice Tools (Customer Supplied) Badger Meter Part Number
• Parallel Pliers 59983-001
• Coax Wire Stripper 59989-001
• Diagonal Cutting Pliers n/a
Using Gel Caps to Connect an Encoder
Follow these steps when using Badger Meter supplied gel caps .
1 . To connect an encoder with existing wires to an ORION endpoint, strip approximately 1-1/2 inches of outer
insulation sheath from the encoder and endpoint cables using a coax wire stripping tool . We recommend using the
Badger Meter Coax Wire Stripper (59989-001) .
USE CAUTION WHEN REMOVING THE OUTER SHEATH SO THAT THE INNER SIGNAL WIRE INSULATION IS NOT
NICKED OR DAMAGED.
2 . Unwind the outer foil shield from the endpoint cable and cut it off even with the outer sheath using diagonal
cutting pliers .
3 . Connect the ORION endpoint to an approved encoder . Verify the endpoint serial number prior to completing the
wiring setup .
• Connect the encoder cable wires to the ORION endpoint wires using the insulation gel caps provided in the
installation kit . Refer to the charts starting on page 9 for the endpoint type and determine which wires need
to be connected to complete an installation .
NOTE: N The terminal posts and wire colors may not match .
DO NOT STRIP ANY INSULATION FROM THE ENDS OF THE WIRES BEFORE YOU PUSH THEM INTO THE
GEL CAP.
• Insert the wires from each cable end as far as possible into the gel cap . See Figure 3: Wires in gel cap .
Page 14 June 2014