User's Manual

Installation Manual
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 stripping tool. We recommend using the Badger Meter
Coax 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 o even with the outer sheath using wire
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 8 for the endpoint type and determine which wires need
to be connected to complete an installation.
OTE: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 27.
Figure 3: Wires in gel cap
• Using a crimping tool such as the Badger Meter Gel Splice Crimping Tool (59983-001), place the gel cap with the
wires into the jaws of the crimping tool.
Figure 4: Gel cap in crimping tool
• Crimp the gel cap by squeezing the crimping tool handles until the gel cap is completely compressed. The crimp
tool is designed to prevent applying too much pressure to the gel cap. Apply pressure for three seconds.
Page 11 May 2014
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